Electromagnetic susceptors with coatings for artificial dielectric systems and devices

ABSTRACT

A coated susceptor of electromagnetic energy for chemical processing made of a matrix material that surrounds a non-matrix material that is made from a material that is different from the matrix material, in which the matrix material is constructed of material having lower dielectric losses compared to the non-matrix material, the non-matrix material initially absorbs electromagnetic energy applied to the electromagnetic susceptor to a greater extent than the matrix material, the non-matrix material produces subsequent heat in the matrix material, and the surface of the susceptor is coated with a material that interacts with applied electromagnetic energy of at least one frequency and initially absorbs electromagnetic energy and produces heat.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 09/897,268, filed on 2 Jul. 2001, allowed and whichwill issue as U.S. Pat. No. 6,512,215 on 28 Jan. 2003, which is adivisional of U.S. patent application Ser. No. 09/402,240, filed on 29Sep. 1999, which issued as U.S. Pat. No. 6,271,509 B1 on 7 Aug. 2001,which is the US National Phase under Chapter II of the PCT of PCT PatentApplication No. PCT/US98/06647 filed Apr. 3, 1998, which published asInternational Publication No. WO 98/46046 on 15 Oct. 1998, which claimsthe benefit of U.S. Provisional Patent Application No. 60/041,942, filedon Apr. 4, 1997.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to a device and process for thermal treatment ofwaste gases and reactive gases. The invention is used for thedestruction and reduction of pollutants from effluent waste streams, andto produce gaseous products from reactant gases. This invention morespecifically relates to a coated susceptor of electromagnetic energy forchemical processing in which a matrix material surrounds a non-matrixmaterial that is made from a material that is different from the matrixmaterial, and the matrix material is constructed of material havinglower dielectric losses compared to the non-matrix material.

2. Prior Art

Devices, which operate on electricity to thermally treat gases fromwaste streams to reduce pollution and thermally react gases forsynthesis of products, do not rely on natural gas for supplying energy.Devices that use natural gas to produce energy for such applicationscreate carbon dioxide, carbon monoxide and nitrogen oxides from theenergy source. Electricity is considered to have cleaner operation whenused in such devices since the above chemical species are not producedduring operation from the heat source. Electric devices for pollutioncontrol applications produce less pollution at the point source whencompared to the counter technologies operating on natural gas. Thereduced pollution is favorable to reduce greenhouse gases and to themeet the requirements of the Clean Air Act of 1990. There are many typesof electric heating methods; this discussion will focus on designs usedto produce heat and reaction with applied electromagnetic energy.

The scope of this current invention is a device for thermal treatment ofgases and pollutants that employs 1) alternate cavity and susceptorgeometries for providing more homogeneous interactions of appliedelectromagnetic energy in the volume of the susceptor regardless of theflow rate and diameter of the exhaust duct width, 2) heat transfermethods to improve the overall heat efficiency of the device, 3) asusceptor structure that has reflectivity as principle mode ofinteraction with applied electromagnetic energy, which allows for energyto penetrate a susceptor, 4) composite susceptor materials, 5) a simplemethod of controlling the temperature versus energy concentration in thesusceptor, and 6) field concentrators to concentrate the energy densityof the applied electromagnetic energy.

Cavity geometries in these devices affect the optical properties of theelectromagnetic energy within the susceptor. Electromagnetic energy,whether ultraviolet, infrared, microwave or radio frequencies, exhibitsthe same optical properties as the visible spectrum when interactingwith geometric shapes and surfaces that are similar to a lens. Theelectromagnetic energy in a susceptor can either converge or diverge dueto the geometric shape of the susceptor following the same principles asoptical lenses. Additionally, the modes of propagation of theelectromagnetic energy are dependent upon the cavities geometry. Thesemodes effect the distribution of electromagnetic energy in the cavity.These modes are different for cylindrical and rectangular cavities (see,e.g., Handbook of Microwave Engineering).

Electromagnetic energy that is incident perpendicular to the perimeterof the circular cross-section of a cylindrical susceptor will convergeinitially, concentrating the energy within the cross-section. Thisconcentration will cause the material inside the susceptor to absorbmore energy than the material near the surface, changing the dielectricproperties of the material inside the cross-section. This concentrationof energy can make the material, which is located in the susceptor'sinterior, between the center and the perimeter, to absorb more energy,thereby reducing the depth of penetration of the material due to thesusceptor's geometry.

The optical properties of rectangular cavities and planar surfaces aredifferent. Rectangular cavities with a susceptor having a rectangulargeometry and planar surfaces will follow the optical properties of aflat surface. A flat surface does not concentrate or disperse energy asdo curved surfaces, such as convex and concave surfaces. With a flatsurface of incidence for applied electromagnetic energy, the absorptionof electromagnetic energy in a susceptor is due only to the propertiesof the materials and is not influenced by energy, which is concentratedby curved geometries. Incident energy on susceptors with flat surfaceswill not be concentrated within a structure with homogeneous material,and the depth of penetration will be influenced by the incident energy'spower, the electric fields and magnetic fields inside the susceptor.Conversely, incident energy on susceptors with curved geometry can beconcentrated within a susceptor with homogeneous materials, and thedepth of penetration of the energy will be influenced by the ability ofthe curved surface to concentrate energy inside the susceptor.

The overall energy efficiency of such devices for thermal treatment ofgases can be improved with a better heat transfer process to capture theenergy that is lost from cooling the tube that is the source for theapplied electromagnetic energy. In industrial microwave dryingoperations, the heat produced from cooling the magnetrons with air isapplied to the articles that are being dried with the microwaves. Thissynergistic drying, which uses hot air and microwaves, increases theenergy efficiency of the drying process.

Alternative composite materials and susceptor structures can be used tofacilitate the thermal treatment of gases. These composite materials andsusceptor structures are known as artificial dielectrics.

Artificial dielectric structures date back to the 1940s. Artificialdielectrics were used as lenses to focus radio waves for communication(Koch). Artificial dielectrics use conductive metal plates, rods,spheres and discs (second phase material) which are embedded in matricesof low dielectric constants and low dielectric losses to increase theindex of refraction, thus reducing size of a lens to achieve the desiredoptical properties. The second phase material reflects the energy anduses diffuse reflection to transmit electromagnetic energy. Theseplates, rods, spheres, and discs can be arranged in a lattice structureto produce an isotropic or an anisotropic structure.

When conductive elements are embedded in a low dielectric constant andlow dielectric loss matrix, the effect of these on the matrix material'sdielectric loss factor is negligible and the dielectric constant of thecomposite lens is increased. However, these above effects are limitedand influenced by the size, shape, conductivity and volume fraction ofthe material embedded in a matrix of low dielectric loss, low dielectricconstant of the material as well as the wavelength of the incidentradiation. The dielectric strength and complex dielectric constant ofthe matrix material plays important additional roles in the design ofartificial dielectric lenses. On the other hand, selection of matrixmaterials with different dielectric properties and incorporation ofsecond phase materials such as semiconductors, ferroelectrics,ferromagnetics, antiferroelectrics, antiferromagnetics, dielectrics withhigher dielectric losses, and dielectrics with conductive losses thatproduce absorption of microwave energy, produce heat in an artificialdielectric.

Lossy artificial dielectrics were demonstrated by the 1950s andsubsequently used at the microwave frequencies to sinter ceramicarticles, in food packaging for heating foodstuffs, in browningapparatuses for foodstuffs, in consumer products, and to renderadhesives flowable for bonding applications.

The structure of the artificial dielectrics determines theelectromagnetic properties. When the volume fraction of the second phasematerials inside the artificial dielectric reaches a certain level, theartificial dielectric will reflect incident electromagnetic energy,shielding the artificial dielectric from absorbing electromagneticenergy. The volume fraction of the second phase material at which theartificial dielectric shields electromagnetic energy is dependent on thesecond phase material's reflectivity, the shape of the second phasematerial, and the temperature. By controlling the amount of reflection,the susceptor's reflectivity can be used to control the susceptor'stemperature.

Reflectivity has been used to produce structures that have aself-limiting temperature. Producing reflectivity in dielectrics isexplained in Von Hipple's Dielectrics and Waves. Using such principles,devices have been designed to have self-limiting temperatures.Self-limiting temperatures have also been theorized for materials withCurie temperatures. The reflectivity of electromagnetic energy isrelated to a material's conductivity. Metals are electrically conductiveat room temperatures and reflective of electromagnetic energy.Semiconductors and ionic conductors have low moderate conductivity atroom temperature. At elevated temperatures semiconductors and ionicconductors have increased conductivity, and these materials will becomereflective to electromagnetic energy at elevated temperatures. Theamount of reflectivity of a material at elevated temperature will alsobe dependent upon the wavelength of incident electromagnetic energy.

The artificial dielectrics structure can be used to produce diffusereflection, or scattering, inside a susceptor. The second phasematerials either can be reflective materials at room temperature, suchas a metal, or can become reflective at elevated temperatures due to 1)increasing conductivity, such as semiconductors and ionic conductorsand/or 2) exceeding the Curie temperature, such as ferroelectrics andferromagnetics. This diffuse reflection may also be used to control thetemperature of a given susceptor that uses the artificial dielectricstructure.

Regardless of the structure of a susceptor and its materials ofconstruction, applied energy must be applied to penetrate the structureand material or materials of construction for volumetric interactionbetween the susceptor and the applied energy.

Other considerations must be given to the structure of a susceptor in adevice for thermal treatment of gases. Honeycombs, foams, packedmaterial and woven structures, which are constructed of a material thateither has an increased dielectric conductivity at elevated temperaturesor has a Curie temperature below the operating temperature could becomereflective. If the material becomes reflective, then the susceptor'sstructure either could a) act as waveguides with dimensions that wouldnot allow the applied energy to penetrate because the applied energywould be below the cut-off frequency for the susceptor's structure or b)shield the electromagnetic energy from penetrating into the susceptor.The Handbook of Microwave Engineering Handbook explains waveguide theoryin more detail. For example, granular suscepting structures employed inU.S. Pat. No. 4,718,358 for treatment of gases exemplify conditionswhere the susceptor's structure may not allow for incidentelectromagnetic energy penetrate the volume of the susceptor.

It seems to appear that the authors of U.S. Pat. No. 4,718,358preferably embody granular absorbing material in the range of about 5 mmto 10 mm with a layer thickness, which is preferably 100 mm to 300 mm.One of the preferred absorbing materials is SiC in granular form.Silicon carbide, a semi-conducting ceramic, has a moderate penetrationdepth of approximately 10 cm at room temperature. And, depending uponthe purity of the SiC, the depth of penetration can be less then 2 cm atroom temperature. At elevated temperatures, silicon carbide becomes moreconductive, thus having an even lower penetration depth. If one assumesthat the granules in U.S. Pat. No. 4,718,358 are spherical, then the 10mm spheres of the SiC would most likely pack inside the cylindricalcavity in what is known as the close-packed cubic structure. Theclose-packed cubic SiC structure would have a void volume of only 26%.The largest void space in this granular pack of 10 mm SiC spheres in theclose-packed cubic structure would be occupied by what is known as anoctahedral site. The octahedral site is the void space between sixspheres—four spheres touching in one plane, one on the top of and one onthe bottom of the void space formed between the four-spheres touching inone plane. The void diameter of the octahedral site at the largestdiameter would be about 6 mm. With an open space of the 6 mm in widthand the device in U.S. Pat. No. 4,718,358 operating at approximately900° C., where the dielectric conductivity of SiC is greatly increasedin comparison to the dielectric conductivity at room temperature, onecan question the ability of the microwave energy at 2.45 GHz andwavelength of approximately 13 cm to propagate through the close-packcubic structure of the SiC granules and heat a volume of SiC with adepth of the particles being between 100 mm to 300 mm. Does the packedSiC spheres at the operating temperature of 900° C. act as a collectionof small waveguides that have dimensions below the cut off frequency forthe applied electromagnetic radiation? If so, the susceptor's structurewill not allow for the applied energy to penetrate into the entirevolume of SiC granules. This type of structure would shieldelectromagnetic energy as exemplified in common practice by windows ofhousehold microwave cooking ovens. Or, does the packing of SiC spheresat an operating temperature of 900° C. have a finite depth ofpenetration that neither allows for the volumetric heating of the entiremass of SiC granules nor has electromagnetic energy throughout thevolume of the SiC mass to interact with gaseous species for possibleenhanced reactions? This latter argument for a finite depth ofpenetration in this susceptor arrangement would most likely heat afinite volume of SiC granules near the surface of the incident appliedradiation, then heat would be thermally conducted through the SiC to theremaining volume of SiC granules since SiC is a very thermallyconductive material. One could argue that a greater power level ofapplied electromagnetic energy could be incident on the SiC granules inan attempt to heat the entire volume, however depth of penetration canbecome less at increased levels of applied power. The greater powerlevel will cause the depth of penetration to migrate to the surfacewhere the applied electromagnetic energy is initially incident upon,when the SiC material becomes more conductive at elevated temperature.The increased conductivity can cause the material to become reflectiveto the applied energy.

Other suscepting structures such as honeycombs, foams and wovenstructures can have similar concerns about the depth of penetrations asmentioned above. These structures, when made of semiconducting,conducting, ferromagnetic, ferrimagnetic, ferroelectric andanitferroelectric materials, can have shallow depths of penetration.Graphite, carbon black, magnetite (Fe₃O₄), MnO₂ are materials that havedepths of penetration less than 1 mm at room temperature. Whensuscepting structures, such as honeycombs, foams and weaves are coatedwith these material, the structures either will have shallow penetrationdepths or will act as waveguides that have dimensions that are below thecutoff frequency regardless of a) the bulk material or materials thatmakes up the substrate for the coating and b) the design of thesusceptor's structure. Consequently, a susceptor must be properlydesigns for volumetric interaction with the electromagnetic energy,taking into consideration the materials of construction, the structureand the effects of coatings.

BRIEF SUMMARY OF INVENTION

This present invention, in its broadest sense, is an improved designthat will produce a more homogeneous distribution of energy by 1) thedesign of the cavity geometry, 2) the location of the applied energysources, and 3) the depth of penetration of the susceptor. The morehomogeneous distribution of energy in the susceptor will provide for theinvention to have the applied electromagnetic energy distributedvolumetrically to a) produce heat, b) be present for interaction withchemical species for destruction of pollutants and to promote chemicalreaction throughout the susceptor, c) to produce fluorescent radiation,and d) to produce thermoluminescent radiation.

The cavity geometry can use polygons that have a cross-section that isirregular shaped, having four (4) or more sides, and preferably arectangle where the cross-sectional area of the rectangle isperpendicular to the direction of flow of the gas stream. The preferredrectangle shape has the location of the applied energy source onopposing faces of the longest parallel sides. The shortest distance ofthe irregular-shaped rectangular cross-section is referred to as thewidth. The width is designed to promote a homogenous distribution ofenergy by design. This design is based upon the depth of penetration ofthe susceptor by the applied electromagnetic energy. The depth ofpenetration of the susceptor is used instead of the depth of penetrationof a material because the susceptor includes the void fraction, thematerial, materials or composite materials of construction and thesusceptor's structure. The depth of penetration of the susceptor isdefined similar to the depth of penetration for a material as mentionedearlier as a value of 1/e. The value of 1/e is equivalent to 67% of theenergy being absorbed or scattered.

The cavity geometry together with the location of the applied energysources and depth of penetration of the susceptor play an important rolein the device. Since the energy sources are located on opposing faces ofthe irregular-shaped rectangle, the distance of one half the width,being the distance from the center of the cross-sectional area to theside of the cavity where the applied energy source is located, isdefined in this invention as the width of interaction. The width ofinteraction is similar to the depth of penetration. The width ofinteraction is used to bisect the susceptor in half to define the depthof penetration of the susceptor upon the half width of the cavity andthe susceptor's surface closest to the location of the applied energysources as described above. The width of interaction is used to describethe amount of energy that is available for interaction within thesusceptor to produce methods that promote chemical reaction anddestruction of pollutants, whereas commonly the depth of penetration ofelectromagnetic energy describes the about of power attenuated inmaterial. Attenuation can result in a material by a) absorption ofenergy to produce heat or b) reflection of the applied energy. In thisinvention, the penetration depth of the susceptor can be use to providefor the destruction of pollutants or reaction of gases by either 1) amethod that primarily produces heat for thermal treatment, 2) a methodthat primarily uses the applied electromagnetic energy for interactionwith gaseous/particulate species for chemical reaction or destruction ofpollutants, 3) a method that produces fluorescent radiation, 4) a methodthat produces thermoluminescent radiation, 5) a method that producesscattering of the applied electromagnetic energy for concentrating theapplied energy, or 6) a combination of these five methods. Thecombination of the methods would be best suited for the purpose at hand.The following examples demonstrate these primary methods:

Example One

If thermal treatment is needed as the primary method for chemicalreaction or destruction of pollutants, then adsorption ofelectromagnetic energy by the susceptor is needed to produce heat in therange for thermal incineration (600-1000° C.) or for catalytic treatment(300-600° C.). To produce volumetric heating in the susceptor by theapplied electromagnetic energy at the operating temperature, then theapplied energy must penetrate the entire width of interaction inside thecavity at the operating temperature. Therefore, the electromagneticenergy must be absorbed by the susceptor, and the depth of penetrationof the susceptor at the operating temperature must allow for the appliedelectromagnetic energy to volumetrically heat the width of interaction.For thermal treatment as the primary method, where the shape of thecavity for this device is an irregular-shaped polygon and the locationof the source of the applied electromagnetic energy is as mentionedabove, the depth of penetration of the susceptor should be approximatelyequivalent to one-third the entire width of susceptor. The depth ofpenetration of the susceptor being approximately ⅓ the width of thesusceptor allows for approximately 50% of the total energy in the cavityfrom the sources of applied energy, which is located at opposing faces,to be present in the width of interaction and to be absorbed by thesusceptor's material or materials of construction.

Example Two

If interaction of electromagnetic energy with the gaseous species is theprimary method for treatment of the gases for chemical reaction ordestruction of the pollutants, then to produce volumetric interaction ofelectromagnetic energy with the gaseous species the applied energy mustpenetrate the width of interaction inside the cavity at the operatingtemperature. Therefore, the electromagnetic energy must be able topenetrate the susceptor, and the depth of penetration of the susceptorat the operating temperature must allow for the applied electromagneticenergy to volumetrically interact with the gaseous or particulatespecies for treatment in the width of interaction. In this method asusceptor may be used to produce turbulence so the gases can mix forbetter conversion of reactant species to product species.

For volumetric interaction of electromagnetic energy with the gaseousspecies, where the shape of the cavity for this device is anirregular-shaped polygon and the location of the source of the appliedelectromagnetic energy is as mentioned above, the depth of penetrationof the susceptor is not as important for this method unless thesusceptor was designed to scatter the applied electromagnetic energy.The depth of the penetration of the susceptor would be designed from amaterial or materials that are primarily transparent to the appliedelectromagnetic energy in order to maximize the amount of applied energyto be present to drive the reaction. Additionally, the susceptors coulduse field-concentrators to increase the strength of the electromagneticenergy (the use of field-concentrators will be disclosed later in thissection). The depth of penetration of the susceptor for this method foreither reacting gases or destroying pollutants would be greater than theentire width of the susceptor and allow for approximately 50% of thetotal energy in the cavity from the sources of applied energy, which islocated at opposing faces, to be present in the width of interaction forinteraction between the applied energy and gaseous/particulate species.However, if scattering the applied energy is the desired for this methodof treatment, then the depth of penetration should be about ⅓ the widthof the susceptor.

Example Three

If a combination of treatment methods is needed as the best method foreither chemical reaction or destruction of pollutants, then adsorption,transmission, reflection and scattering of electromagnetic energy orenergies by the susceptor may be required. Absorption of the appliedelectromagnetic energy in the susceptor either could produce heat, orcould produce fluorescent radiation emissions, thermoluminescentradiation emissions or assist in producing fluorescent radiation. Forexample, an applied ultraviolet (UV) energy source can be used toproduce phosphorescent radiation in a susceptor or at a fieldconcentrator for interaction between the phosphorescent radiation andthe gaseous/particulate species to drive the reaction. The applied UVenergy can also interact with the gaseous/particulate species. Such amaterial for the susceptor or field concentrator could be aphosphorescent material.

The depth of penetration of susceptor must allow for applied UV energyto penetrate the susceptor for volumetric interaction a) with thesusceptor to produce fluorescent radiation and/or b) directly betweenthe applied UV energy and gaseous/particulate species. Consequently, ifUV and microwave energies are applied to the same susceptor, otherinteractions may occur between the applied energies, material ofconstruction of the susceptor, field concentrators and the gaseousspecies (or particulate). The UV energy that is applied to the cavitycan interact as previously mentioned, however the microwave energy a)may produce thermoluminescence in the phosphorescent materials b) mayproduce heat in the susceptor by the applied microwave energy and/or c)may enhance the phosphorescent radiation produce primarily by theapplied UV energy. Of other consequence, if the applied energy to thesame susceptor is only microwave energy then other interactions mayoccur. The microwave energy either a) may be completely absorbed forthermal treatment of the gases, b) may be partially absorbed andinteract with the gaseous species for interaction, c) may be used toheat the susceptor and produce thermophosphorescence of UV radiation,which interacts with the gaseous species, or d) a combination of thementioned interactions in a, b, and c.

This example, example three, demonstrates the potential complexity ofthe interaction of the applied electromagnetic energy, fluorescentradiation and thermoluminescent radiation with the susceptor's materialof construction and the susceptor's construction. As previouslymentioned in the Background section, the material or materials ofconstruction as well as the structure of the susceptor will influencethe ability of the applied electromagnetic energy or energies topenetrate and interact with the susceptor a) to produce heat, b) to bepresent for interaction with the gaseous/particulate species, c) toproduce fluorescence, and d) to produce thermoluminescence. Likewise,the ability of fluorescent and thermoluminescent radiation to penetratefinite distances within the susceptor's structure and interact with thegaseous/particulate species in the air stream for chemical reaction ordestruction of pollutants could be of importance to the design of thesusceptor. Fluorescent radiation could be phosphorescence, incandescenceor fields generated by thermionic emissions or thermoelectricityemissions.

In example three, the transmission of, absorption of, reflectivity ofand scattering of each wavelength of energy that is present in thesusceptor becomes important. Instead of the susceptor being constructedof a material, the susceptor may better be constructed of more than onematerial, which will allow for the wavelength or wavelengths of theapplied electromagnetic energy or energies to penetrate andvolumetrically interact with the susceptor. And the construction anddesign of the susceptor and the susceptor's materials of constructionwill have to be chosen to prevent the design of the susceptor'sstructure from shielding the wavelength or wavelengths of the appliedelectromagnetic energy and energies. And also, transmission, absorption,reflectivity and scattering properties of the susceptor will be effectedby the bulk density of the materials of construction, as well as theporosity size, pore structure and amount porosity in the materials ofconstruction.

This invention, in its broadest sense, is an improved design which usescavity geometry that has a cross-section, which is perpendicular to theflow of the gas stream, and is shaped as an irregular shape, having four(4) or more sides, preferably a rectangle. The preferred rectangle shapehas the location of the applied energy source on opposing faces of thelongest parallel sides of the cross-section area perpendicular to theflow of the gas stream. The location of the applied energy source andthe geometry of the cavity and susceptor does not allow for the opticalproperties of the device to concentrate energy, thus simplifying thedesign of a susceptor for interaction with the applied electromagneticenergy and producing a more homogeneous distribution of electromagneticenergy in the cavity.

When the susceptor is designed for a specific method a treatment of thegas stream, the design will be only be dictated by the depth ofpenetration of the susceptor which is dependent upon the chosen width ofinteraction of the susceptor, since energy is not concentrated.Therefore, once a method for treatment of the gas stream is chosen, oncean amount of power of the applied electromagnetic energy or energies ischosen and once a width of interaction is decided upon to reduce thestatic-pressure in the device, the susceptor's materials of constructionand susceptor's structure can remain constant when the device is to bescaled for larger flow rates and larger exhaust duct width in commercialand industrial applications. To accommodate larger flow rates or largerexhaust duct widths, only the length of the cross-sectional area of theirregular-shaped polygon where the energy source or sources are locatedcan simply be elongated. Unlike cylindrical cavities, the absorptionproperties of the susceptor's material or material of construction donot have be changed to accommodate greater flow rates and larger ductwidths of commercial and industrial process for volumetric heating orinteraction of the applied energy with the gases inside the devicesusceptor.

With the design of the device in this invention, proper thermaltreatment of the pollutants can be achieved. Since this designsimplifies the susceptor for producing heat at a wide variety of flowrates and duct widths, one can readily design devices for proper thermaltreatment of gases by selecting an operating temperature and by sizing alength of a hot zone for the required residence time at the operatingtemperature and turbulence in the susceptor. Thermal insulation aroundthe susceptor may be needed to prevent heat losses. Material that istransparent to the applied electromagnetic energy or energies and thatuses an aerogel structure would be best suited for thermal insulation.An aerogel is a structure that has over 96% porosity and a bulk densityof 4%. The hot zone's length would be designed in the coaxial directionof flow of the air stream where the direction is the defined breadth ofthe device.

In this broadest sense of the invention, the cavity's geometricalcross-sectional area perpendicular to the flow of the air stream and thesusceptor's width of interaction is designed to provide in this device amore homogenous distribution of energy with a given amount of appliedpower. With the more homogeneous distribution of energy, the inventionallows for one to design a method for specific treatment of gaseous andparticulate species, compared to designing treatment methods withdevices that have geometries that concentrate electromagnetic energysuch as a cylinder. With this invention, the depth of penetration of thesusceptor by the applied electromagnetic energy or energy allows one todesign methods of destroying pollution and reacting gases/particulatespecies. When the depth of the penetration of the susceptor is one third(⅓) the width of the susceptor's total width or greater, the method oftreatment of gases/particulate can be either 1) primarily thermal, 2) acombination of thermal, fluorescent, thermoluminescent, and interactionbetween the applied energy or energies and the gas or particulate in theair stream, or 3) when scattering of the applied energy is used toconcentrate the applied energy without producing substantial heating ofsusceptor, such as with a low loss, low dielectric constant susceptorconstructed with metallic spheres and fused silica, the device canprimary treat by interaction between the applied energy or energies andthe gas or particulate in the air stream:

The design is improved over the prior art because the prior art usedcylindrical geometries. Cylindrical geometries tend to concentrateenergy in a susceptor. Concentrated energy can lead to several problemswhen operating the device. One concern is the concentrated energypromotes conditions that lead to thermal runaway. The runaway can causethe susceptor's material or materials to melt, creating a pool of liquidmaterial in the susceptor. Another concern is that the concentratedenergy will not allow the applied energy to volumetric heat a susceptor.Such concentration will require the absorbing properties of thesusceptor's material of construction to be graded to counteract theconcentration, however this may not help. Also, susceptors incylindrical cavities are more difficult to scale up to greater flowrates and duct widths because of the absorption properties. Anotherconcern is that the concentrated energy can lead to deleterious reactionbetween composite materials and coatings on substrates. The deleteriousreaction can cause the materials to melt at eutectic temperature, causean article to become friable and alter the interaction between theapplied electromagnetic material and the susceptor, changing theproperties for subsequent use.

Another aspect of this invention is a heat transfer process to increasethe efficiency of such devices, which treat gases for chemical reaction,or destruction of pollutants. Commercially available magnetrons aregenerally between 65-70% efficient. Therefore 30-35% of the energy thatis initially put into the system is lost. An aspect of this invention isa heat transfer process for using that energy.

In this heat transfer process, heat is transferred between heat energythat is produced by the tube or tubes which supplies the appliedelectromagnetic energy and an input chemical species flow that cancontain gases and particulate species. The process uses the heat fromthe tubes or tubes to preheat the input chemical species flow, or partof the input chemical species flow, prior to it entering the device.This heat transfer process for preheating the input chemical speciesflow will decrease the cost of operating such a device. The heat fromthe tube, or tubes, can be exchanged with the input chemical speciesflow by such cooling fins that are found on commercial magnetrons, heatpipes, thermoelectric devices, or cooling systems that circulate a fluidaround the tube and release the heat at radiator. After the inputchemical species flow is preheated with heat from the tube, the inputchemical species flow can be further heated by heat transfer either a)from the cavity walls, b) from a conventional heat exchanger (arecuperator) that is located after the exit end of the device, or c)from both the cavity walls and a conventional recuperator.

Another aspect of this invention is a susceptor design that is describedin this invention as a gas-permeable macroscopic artificial dielectric.The gas-permeable macroscopic artificial dielectric susceptor device canbe a honeycomb structure, foam, or woven fabric filter with a pattern,or a structure consisting of discrete susceptors. The macroscopicartificial dielectric susceptor can be designed a) for a specific cavitygeometry, b) for a specific depth of penetration of applied andsubsequent radiation produced from the applied radiation, c) to betemperature self-limiting, or d) to produce, in the macroscopicartificial dielectric susceptor, a desired ratio of a self-limitedtemperature to power concentration of applied electromagnetic energy atone or more frequencies.

This aspect of the invention distinguishes the term artificialdielectric by using an artificial dielectric material and a macroscopicartificial dielectric susceptor. An artificial dielectric material isused to describe the case where an article is constructed of compositematerial consisting of two or more materials each with differentdielectric properties, where one material is the matrix and the othermaterial is or other materials are embedded in the matrix withoutsubstantial chemical reaction between the matrix and the embedded inmaterials. A macroscopic artificial dielectric susceptor is used todescribe a susceptor that is either a) an article constructed of amaterial where the article has a coating applied in a specific patternto create an artificial dielectric structure from the coating and thearticle, b) a woven structure that contains two or more differentmaterials as threads (or yarns) which woven together to form anartificial dielectric structure, or c) a structure that consists of amixture of discrete suscepting articles where the mixture containsdiscrete articles that have different dielectric properties and surroundeach other to form an artificial dielectric structure.

When the susceptor is a gas-permeable macroscopic artificial dielectricstructure that is a honeycomb structure constructed of materials, someof the cell walls of the honeycomb can be coated with materials thathave different dielectric properties to produce a macroscopic artificialdielectric. The pattern of cells with coated walls are arranged in thehoneycomb so that the applied electromagnetic energy and energiespenetrate the suscepting structure and either heat the susceptor orscatter the energy for interaction with the gases/particulate in the airstream. The pattern of the cell walls attenuate the appliedelectromagnetic energy by either a) partially or completely by absorbingthe applied energy, producing fluorescent radiation to heat theremaining parts of the susceptor and the air stream or b) partially orcompletely scattering applied energy to concentrate the applied energyfor interaction with the air stream or to heat the remaining volume ofthe susceptor. Also, a macroscopic artificial dielectric can be madefrom the honeycomb structure by filling some of the cells with anothermaterial. Additionally, a large honeycombed-shaped, macroscopicartificial dielectric structure can be constructed from 1) smallerdiscrete susceptor articles that are small honeycombed shaped articlesthat have differing dielectric properties and/or conductivity or 2)smaller discrete susceptor articles that are honeycombed shaped thathave the same dielectric property and are cemented together with amaterial which has different dielectric properties and/or conductivity.

It is understood by one who reads this that the same or similar methodsused to create honeycombed-shaped macroscopic artificial dielectrics canbe employed to create macroscopic artificial dielectrics out of foamsand weaves.

When the macroscopic artificial dielectric susceptor is designed as adevice with a structure consisting of discrete susceptors, the susceptorcan be designed for complex interaction with the applied energy orenergies as previously described in Example Three. Potentially, eachdiscrete susceptor can have separate characteristics for absorption,transmission, scattering and reflection of 1) applied electromagneticenergy or energies, 2) subsequent fluorescent radiation produced fromthe applied electromagnetic energy or energies, and 3) the subsequentradiation from heat resulting from the dielectric loss within eachindividual susceptor. The discrete susceptors in this invention areknown as unit susceptors. The separate characteristics of absorption,transmission, scattering and reflection of a unit susceptor are effectedby the unit susceptor's length, thickness, shape, composite materialsstructure, material selection, porosity, pore sizes, temperaturedependence of the complex dielectric constant and thermal conductivity.

Since macroscopic artificial dielectric susceptors are made from amixture of unit susceptors, one is capable of designing a variety ofsusceptor structures. The versatility using unit susceptors will beapparent with the following discussion. Although the optical propertiesof each unit susceptor within the macroscopic artificial dielectric canbe independent, the structure of the macroscopic artificial dielectricsusceptor will dictate the interaction of the macroscopic susceptor withthe applied electromagnetic energy. The structure of the macroscopicartificial dielectric susceptor will be described with the unitsusceptors that are primarily reflective. The reflectivity of the unitsusceptors can be produced from either metallic or intermetallicmaterials species at room temperature or materials such assemiconductors, ferroelectrics, ferromagnetics, antiferroelectrics, andantiferromagnetics that become reflective at elevated temperatures. Thematerials that produce reflection can be a) homogeneous, b) compositematerials having a second phase material in a matrix that is partiallyabsorptive to applied electromagnetic energy where the volume fractionof the second phase materials can be used to control the amount ofreflection of a unit susceptor, or c) coatings on a unit susceptor.Also, the length, width and shape of the unit susceptors and thedistance between reflective unit susceptors can be controlled by thereflectivity of the gas-permeable macroscopic susceptor.

The shape of the unit susceptor can be designed for reflection. Theshape of the unit susceptor can be chiral, spire-like, helical,rod-like, acicular, spherical, ellipsoidal, disc-shaped, needle-like,plate-like, irregular-shaped or the shape of spaghetti twist in Muller'sSpaghetti and Creamette brand. The shape of the unit susceptor can bedesigned to produce turbulence in the air flow, thus providing formixing of reactants in the gaseous or liquid stream. The shape and sizeof the susceptor can be used to grade the pore size of the susceptor toaccommodate the expansion of gas due to passing through the hot zone.

The temperature dependent materials that are used in unit susceptors canbe used to produce a temperature self-limiting macroscopic susceptor aswell as to produce in the macroscopic dielectric a desired ratio of aself-limited temperature to power concentration of appliedelectromagnetic energy at one or more frequencies. The above-mentionedstructures can be produced and the desired effects achieved bycontrolling the volume fraction, size and shape of the unit susceptorsand the transmission, reflection, absorption and scattering produced bythe materials selection for each unit susceptor.

The macroscopic artificial dielectric susceptor works on the principleof reflection and diffuse reflection, scattering. The reflectivity ofthe macroscopic artificial dielectric susceptor is controlled by thevolume and interconnectivity of the unit susceptors which are theprimarily reflective unit susceptors in the macroscopic susceptor. Theprimarily reflective unit susceptors are defined as being the unitsusceptors which are primarily reflective to the applied energy orenergies. The gas-permeable artificial dielectric susceptor has theprimarily reflective unit susceptors surrounded by unit susceptors thatare either primarily transparent or primarily absorptive of the appliedenergy or energies. As the volume of the primarily reflective unitsusceptors increases in the macroscopic susceptor, a degree ofinterconnectivity of the primarily reflective unit susceptor will occur,forming an interconnective network within the macroscopic artificialsusceptor. The degree or amount of interconnectivity will depend on thesize and shape of the primarily reflective unit susceptors. The abilityof the applied energy or energies to penetrate the macroscopicartificial dielectric susceptor will depend not only on the volume ofthe primarily reflective unit susceptor but also on the degree andamount of interconnectivity. When the degree of interconnectivity of theprimarily reflective unit susceptors throughout the entire gas-permeablemacroscopic susceptor is such that maximum distance between theinterconnected network of the primarily reflective unit susceptors doesnot allow for applied energy to penetrate or the longest wavelength ofthe applied energies to penetrate, the gas-permeable macroscopicsusceptor, itself, will become primarily reflective to either a) theapplied electromagnetic energy or b) the longest wavelength of theapplied energies. In some instances, a high degree of interconnectivityis desired.

A high degree of interconnectivity can be beneficial in some instances.Clusters of primarily reflective unit susceptors can be distributedabout the macroscopic artificial susceptor to promote scattering.Primarily reflective unit susceptors can be aggregated to form shapesand boundaries that reflect one or more wavelengths of the appliedenergy or energies. The volume fraction and interconnectivity of thereflective unit susceptors surrounding primarily absorbing or primarilytransparent unit susceptors can be used to design specific macroscopicartificial dielectric structures a) for resonant cavities with that arebased upon the wavelength of the applied energy in the susceptor, b) forscattering energy for interaction with gas or particulate species, c)that concentrate energy at field concentrators which are located onother unit susceptors, d) that concentrate energy within the susceptorfor increased reactivity between the gas stream and the fluorescentradiation, e) that have the primarily reflective unit susceptorsarranged in such a manner to produce a large spiral, helical or othershape with the macroscopic susceptor, f) that act as shielding toprevent the applied electromagnetic from entering material inside thecavity for thermal insulation, g) that prevent leakage outside thecavity by the applied energy, h) that reflect applied energy to otherregions of the artificial dielectric to provide either highertemperatures or increased energy for reaction or destruction ofgaseous/particulate species and i) possibly, that regulate thetemperature of the gas-stream.

The several benefits and advantages of this invention compared todevices of prior art will become apparent to one skilled in the art whoreads and understands the following examples of this invention'sempirical results. Table 1 contains data from several gas-permeablemacroscopic artificial dielectrics susceptors that were exposed toapplied electromagnetic energy of a frequency of 2.45 Ghz in thisinvention's cavity as described as having a rectangular cross-sectionalarea perpendicular to the direction of the gas stream's flow. Thelocation of the applied energy's source was as mentioned previously.Each of the following examples of the gas-permeable, macroscopicartificial dielectric susceptor uses unit susceptors.

A type-K thermocouple was inserted into the cavity after the time shown.Prior to inserting the thermocouple, all power to the magnetrons wasturned off. In these examples, the unit susceptors that are designatedas an aluminosilicate (AS) ceramic were made from an 85/15 weightpercent mixture of EPK Kaolin/KT Ball Clay. The unit susceptors that aremade of artificial dielectric materials have an aluminosilicate matrixmade from an 85/15 weight percent mixture of EPK Kaolin/KT Ball Clay.The composition of the unit susceptors that are made from artificialdielectric materials are designate by AS—(volume percent of second phasematerials), i.e. AS-12 SiC. The particle size of each second phasematerial was less then −325 US mesh size. The time to produce a visibleglow—that is, red heat—was observed visually. All examples were separatetests.

The gas permeable macroscopic artificial dielectric susceptor wasexposed to approximately 12.6 KW of power from 16 800 watt magnetrons.The dimensions of the cross-sectional area perpendicular to direction offlow were 7 inches in width and 14 inches in length. The breadth of thecavity was 22 inches. Eight magnetrons were located on each side of theopposite sides of the largest parallel side of the cross-sectional area.On each side, the eight magnetrons were grouped in pairs, and the fourpairs were group one after another along the breadth of the cavity. Inthese examples from experimental results, all unit susceptors are shapedas spaghetti twists (rotini). The spaghetti twists produce a largeamount of free volume within the macroscopic artificial dielectricsusceptor, over 70% free volume.

The result of experiments in these examples show the uniqueness of thisinvention, and the implications of these results that show severaladvantages over the prior art will become clear to the reader afterunderstanding the discussion of the results.

Discussion 1: When the results of Examples 4 and 5 are compared, onefinds that the greater volume percentage of SiC, which makes anartificial dielectric material within the unit susceptors, decreases thetime to show a red glow and increases the temperature after one hour.The macroscopic susceptor of Example 4 is constructed of only unitsusceptors that have a composition of an aluminosilicate ceramic matrixcontaining 6 vol. % −325 mesh SiC, required 51 minutes to show a redglow and after one hour had a center temperature of 803° C., whereas themacroscopic susceptor of Example 5 is constructed of only unitsusceptors that have a composition of an aluminosilicate ceramic matrixcontaining 12 vol. % −325 mesh SiC, required 27 minutes to show a redglow and after one hour had a center temperature of 858° C. In comparingExample 4 with Example 5, one finds that a greater percentage of SiC inthe macroscopic susceptor produced a faster heating rate and a highertemperature the macroscopic susceptor.

TABLE 1 Time to Weight % of each show a unit susceptor type red glowTemp. in macroscopic in the after one Example susceptor device hourComments 4 100% AS - 6 SiC 51 min 803° C. 5 100% AS - 12 SiC 27 min 858°C. 6 100% AS 29 min >1260° C. susceptor's temperature exceed the limitof the type-K thermo- couple 7 50% AS 36 min 1006° C. 50% AS - 12 SiC 850% AS 39 min 1008° C. temperature 50% AS - 12 SiC after 3 hours 9 50%AS 32 min 1006° C. temperature 50% AS - 12 SiC after 4 hours and 30minutes 10 56% AS 6 min 1142° C. 23% AS - 30Cr₂O₃ 12% AS - 30 Chromate6% AS - 30Fe₂O₃ and Chromate 3% AS - 30Fe₂O₃ 11 18% AS - <2 min, had to2 of the 16 30 Chromate then the shut magnetron glow down tubes melted19% AS - 30 Cr₂O₃ disap- after 30 from the 32% AS - peared. minutes.back reflec- 30Fe₂O₃/30Cr₂O₃ tion off the 9% AS - gas perme- able macro-30 Chromate/ scopic sus- 30Fe₂O₃ ceptor. Here 3% AS - 30Fe₂O₃ the large19% AS - 30CaTiO₃ volume and high degree of intercon- nectivity produceda very reflec- tive macro- scopic susceptor.

Discussion 2: When the results of Examples 5 and 6 are compared, onefinds that the greater volume percentage of SiC, which makes anartificial dielectric material within the unit susceptors, does notgreatly effect the time to show a red glow and decreases the temperatureafter one hour when compared to unit susceptors that are just made fromthe aluminosilicate ceramic matrix material. The macroscopic susceptorof Example 6 is constructed of only unit susceptors that have acomposition of an aluminosilicate ceramic matrix containing 12 vol. %−325 mesh SiC, required 27 minutes to show a red glow and after one hourhad a center temperature of 858° C., whereas the macroscopic susceptorof Example 6 is constructed of only unit susceptors that have acomposition of the aluminosilicate ceramic matrix contain 0 vol. % −325mesh SiC, required 29 minutes to show a red glow and after one hour hada center temperature that was greater than 1260° C. In comparing Example5 with Example 6, one finds that the 12 vol. % of SiC in the macroscopicsusceptor of Example 5 suppresses the temperature of the macroscopicsusceptor as compared to the macroscopic susceptor that was constructedof unit susceptors that are constructed of the aluminosilicate matrixalone.

Comparison between Discussion 1 and Discussion 2: In Discussion 1, theincreased volume percentage of SiC in the unit susceptors, which areconstructed of an artificial dielectric material, shows that the greatervolume of SiC in an artificial dielectric material increased theabsorption of the applied electromagnetic energy; the heating rate andtemperature after one hour increased. In Discussion 2, the resultsshowed that the macroscopic susceptor without the artificial dielectricmaterial, (AS-vol. % SiC), had a) about the same heating rate as theartificial dielectric material with 12 vol. % SiC and b) a highertemperature than the artificial dielectric material with 12 vol. % SiC.One can understand that the greater SiC content in the artificialmaterial in Example 5 compared to Example 4, increases the absorption ofmacroscopic susceptors.

One can also understand that when one compares Example 5 to Example 6,one finds that the absorption of the applied energy by the unitsusceptor, which is made of an artificial dielectric material,suppresses the temperature after one hour. This suppression of thetemperature can be due to the reflectivity of the SiC as the temperatureof the SiC increases.

Discussion 3: When one compares Example 7 with Example 4, one findsintriguing results. Example 7 uses a macroscopic artificial dielectricsusceptor made from a 50/50 mixture of two types of unit susceptors. Onetype of unit susceptor is the primarily reflective and is constructed ofan artificial dielectric material, AS-12 SiC, the material used inExample 5. The other type of unit susceptors is the primarily absorptiveunit susceptor material and is constructed of the AS material that wasused in Example 6. The 50/50 mixture of the two types of unit susceptorsdid not produce an interconnective network between the primarilyreflective unit susceptors. When one carefully compares the results fromExample 4 and Example 7, one finds that the total amount of SiC on themacroscopic susceptor for the unit susceptor that is constructed of theartificial material, AS-6SiC in Example 4 is approximately equal to thetotal volume of SiC in the macroscopic artificial dielectric susceptorin Example 7. In Example 7, the 50/50 mixture of the AS unit susceptorsand the AS-12 vol. % unit susceptors produces approximately the samevolume of SiC in the macroscopic susceptor as Example 4. However,Example 7 has faster time to show a red glow then Example 4 and a highertemperature after one hour (1006° C.). Absorption by the total volume ofSiC in the macroscopic susceptor cannot be fully responsible for theresults in Example 7. It is the structure, the macroscopic artificialdielectric susceptor, that is responsible for the increased time to showa red glow and a higher temperature after one hour (1006° C.).Therefore, the structure of the macroscopic artificial dielectricsusceptor that contains the primarily reflective unit susceptors thatare mixed with the primarily absorptive susceptors, must be having theprimarily reflective unit susceptors reflecting, or scattering theapplied energy and the scattered (reflected) energy is being absorbed bythe primarily absorptive unit susceptors. The primarily reflective unitsusceptors are concentrating the energy within the macroscopicartificial dielectric susceptor.

Discussion 4: When one compares the results from Examples 7, 8 and 9,one finds that the macroscopic artificial dielectric structure canproduce a self-limiting temperature, and since it can produce aself-limiting temperature, the gas-permeable macroscopic artificialdielectric structure should allow one to design macroscopic artificialdielectric structures to a desired self-limiting temperature to powerconcentration of applied energy or energies to heat gases, treatpollutants in a gas stream and to react chemical species in a gasstream.

Discussion 5: The results of Example 10 show an effect one finds whenthe gas-permeable macroscopic artificial dielectric susceptor isconstructed of primarily reflective unit susceptors which are made froman artificial dielectric material that contains a greater volumepercentage of semi-conducting and materials with a Curie temperature.The primary reflective unit susceptors were constructed of an artificialdielectric containing 30 vol. % of −325 mesh materials that were eitherCr₂O₃, Fe₂O₃, chromate or a mixture containing two of the threematerials. The matrix of the artificial dielectric material was the ASmaterials. The gas-permeable artificial dielectric that was constructedfrom these primarily reflective unit susceptors had a very fast time toshow a red glow and a high temperature (1142° C.). Example 10 shows thatthe amount of reflection of the primarily reflective susceptorsinfluences the heat rate of, temperature of and energy concentrationwithin the macroscopic artificial dielectric susceptor. One canunderstand that the amount of reflection also should allow one to designmacroscopic artificial dielectric structures to a desired self-limitingtemperature to power concentration of applied energy or energies to heatgases, treat pollutants in a gas stream and to react chemical species ina gas stream as well as will increase the energy concentration withinthe artificial dielectric susceptor.

Discussion 6: Example 11 exemplifies what happens when the volumefraction and the interconnectivity of the primarily unit reflectivesusceptors become too great. At first one sees that a very fast time toshow a red glow red is present, then the glow disappears. What hashappened in this example is that the temperature of the primarilyreflective unit susceptors increased by absorbing the applied energy,and then the increased temperature caused the primarily reflective unitsusceptors either to have Curie temperature to be exceeded, to havegreater reflectivity or both in the unit susceptors' materials ofconstruction. With the increase reflectivity, Curie temperatureexceeded, high volume fraction of the primarily reflective unitsusceptor and extremely high degree of interconnectivity of theprimarily reflective unit susceptors, the macroscopic artificialdielectric susceptor became reflective and did not allow for the appliedenergy to volumetrically interact with the macroscopic artificialdielectric susceptor. The back reflection from the macroscopicartificial dielectric susceptor destroyed two microwave tubes.

Of importance is the structure of a macroscopic artificial dielectricsusceptor. The structure should allow for applied electromagnetic energyto penetrate the distance between the primarily reflective components,whether a discrete susceptor, coating or woven structure so thestructure does not act as a collection of waveguides with cut-offfrequencies that prevent the applied energy from penetrating the widthof interaction.

Another aspect of this invention is the use of the structure of themacroscopic artificial dielectric susceptor for adsorption, regenerationand desorption of gaseous reactants or pollutants. The structure can beused with such devices known in the field of pollution control as rotaryconcentrators or other devices that use adsorption in a process to treatto pollutants. Typically in such devices, a zeolite material oractivated carbon is used to adsorb gaseous species. Other forms ofcarbon also can be used. The penetration depth of carbon in the form ofan article tends to be about one micron, and in loose powder, thepenetration depth can be 3 mm. Zeolite materials, depending upon theirdoping, have much greater penetration depths.

A macroscopic artificial dielectric susceptor can be made from a mixtureof unit susceptors. The mixture would contain unit susceptors made withactivated carbon and unit susceptors made with zeolites. Also, unitsusceptors can be made from either a) artificial dielectric materialshaving a zeolite as the matrix and a carbon species as the second phase,b) artificial dielectric materials having a carbon species as the matrixand zeolite species as the second phase, or c) unit susceptors that arecoated with a carbon species, preferably activated carbon. As in thekeeping with the aspects of this invention, the structure of amacroscopic artificial dielectric susceptor should allow for appliedelectromagnetic energy to penetrate the distance between the primarilyreflective components, whether a discrete susceptor, coating or wovenstructure so that the structure does not act as a collection ofwaveguides with cut-off frequencies that prevent the applied energy frompenetrating the width of interaction.

Another aspect of this invention is the use of semi-conducting metalsand ceramics, ionic-conducting ceramics, ferromagnetic, ferrimagnetic,ferroelectric and antiferroelectric materials for their reflectivecharacteristics of the applied electromagnetic energy. These types ofmaterials tends to be primarily absorbing materials as articles or largeparticles (particle sizes greater than 250 microns), however when theparticle size of these types of materials are 50 microns or less thesesemi-conducing materials greatly absorb the applied energy, especiallywavelengths in the microwave region, and reach very high temperatures,becoming very conductive. When these materials become very conductive athigh temperatures, they become very reflective. Reflective behavior fromthe small particle-size SiC in the unit susceptors that were constructedof artificial dielectric materials, not the volume fraction of the SiC,is the only way to explain the different behavior between Example 4,Example 5 and Example 7. In this invention, SiC is used as a hightemperature reflector.

The conductivity of these types of materials as well as other ceramicmaterials, mentioned above can be controlled by cation and anionsubstitution on the lattice structure of the materials. Typically, theamount of substitution of cation or anion on a lattice structure of amaterial would be less than 15 mole percent.

The absorption, transmission, reflection, scattering and the complexdielectric constant of unit susceptors can be controlled by usingcomposite materials. These composite materials are artificialdielectrics, layered or coated composites, having a matrix materialcontaining a second phase or third phase which have a particle diameterless than −325 US mesh size. The composite materials for unit susceptorscan use combination of materials in such a fashion where the matrix isa) a metal forming a cermet, b) polymeric organic materials, c) apolycrystalline ceramic, d) a glass/ceramic material, and e)intermetallic. Materials for the matrix, substrate for a coated unitsusceptor or entire unit susceptor include a) aluminosilicates andsilica derived from clays or mixture of clays, b) alumina, c) MgO, d)stabilized and partially stabilized zirconia, e) magnesium silicates andsilica derived from talcs, f) enstatite, g) forsterite, h) steatite, i)porcelain ceramics, j) cordierite, k) fused silica, l) stainless steel,and m) cast iron. The second phase materials can be 1) athermoluminescent material, 2) a phosphorescent material, 3) anincandescent material, 4) ferroelectric, 5) ferromagnetic, 6)ferrimagnetic, 7) MnO₂, 8) TiO₂, 9) CuO, 10) NiO, 11) Fe₂O₃, 12) Cr₂O₃,13) Li₂O doped MnO₂, 14) Li₂O doped CuO, 15) Li₂O doped NiO, 16)CuO—MnO₂—Li₂O complex, 17) CuO—MnO₂, 18) silicide, 19) borides, 20)aluminides, 21) nitrides, 22) carbides, 23) ceramic glazes with metalparticles, and 24) ceramic glazes with semi-conducting particles. Theshape of the second phase materials can be chiral, spire-like, helical,rod-like, acicular, spherical, ellipsoidal, disc-shaped,irregular-shape, plate-like or needle-like.

Another aspect of this invention is a conceptual design of the structureof a unit susceptor's artificial dielectric material that increases thechemical compatibility between the matrix and second phase material. Thesize of the second phase material can be used to control the chemicalcompatibility between the matrix and the second phase material. Largerparticle sizes of the second phase material will make the second phasematerials more compatible with the matrix. In this invention, where thesecond phase material has questionable compatibility with the matrix thesecond phase material is to have a particle size between 200 microns and4 mm. Chemical incompatibility can lend to melting or other solid-statereactions at the interface between the matrix and the second phasematerial. The melting and solid-state reactions can lead to greaterabsorption, and possible to a situation that leads to thermal runaway inthe material.

Another aspect of this invention is the design of unit susceptors thathave artificial dielectric materials that have compatible thermalexpansions between the matrix and the second phase material. Poorthermal expansion compatibility can lead to friable unit susceptors fromthermally cycling the device during operation. The two methods that thisdevice uses are a) materials where the thermal expansion mismatch isless than 15% and b) the matrix and the second phase material has thesame lattice structure and principle composition, but the latticestructure of the second phase material is doped with a cation or ananion to change the electrical resistance of the second phase materialin the artificial dielectric material. Using the spinel structure asexamples, the matrix material can be MgAl₂O₄ and the second phasematerial would be (Mg,Fe)Al₂O₄, and the matrix of Fe₂O₃ and the secondphase material is Fe₂O₃ doped with TiO₂. Additionally, the matrix can beAlN and the second phase materials can be AlN doped with Fe⁺³.

The thermal conductivity of the unit susceptor can be controlled forheat transfer. The thermal conductivity can be controlled by either a)porosity of the material of the unit susceptor, b) the compositestructure of the unit susceptor, c) high thermally conductive materialssuch as from high purity nitrides, aluminides, silicides, borides andcarbides, d) highly thermally conductive coatings can be used as coatingon porous unit susceptors to increase the thermal conductivity at thesurface, or e) grading the pore structure by flame polishing the outersurface of the susceptor.

Another aspect of this invention is the use of unit susceptors orcoatings on unit susceptors that are sacrificial. The sacrificialsusceptors or coatings are used in either in chemical reactions or usedto treat pollutants. For example, to eliminate NOx from polluted gasstreams, NOx can be reacted with carbon to produce N₂ and CO₂. In thisexample carbon is needed as a reactant. Therefore, unit susceptors orcoating on unit susceptors could be made with carbon that issacrificial. After the carbon-containing unit susceptors are used up,the macroscopic artificial dielectric structure can be replenished withthe new carbon-containing susceptors. The form of carbon can beactivated carbon, carbon black, soot, pitch, or graphite.

Another aspect of this invention is the use of field concentrators onthe surface of the unit susceptors. The field concentrators concentratethe electromagnetic field locally so a high intensity electromagneticfield is available to interact with gaseous/particulate species toeither drive chemical reaction, enhance the reaction between chemicalspecies or to treat pollutants. The field concentrator would be madefrom either a) conductors, b) semiconductors, c) materials with a Curiepoint, d) ionic-conducting ceramic, e) composite materials from a and c,f) composite materials from b and c, g) composite materials from a andd, and h) composite materials from b and d. The shape of the compositematerials can be chiral, spire-like, helical, rod-like, acicular,spherical, ellipsoidal, disc-shaped, irregular-shape, plate-like,needle-like or have a shape that has sharp-pointed-gear-like teeth. Thesize of the field concentrators can be one to 10 times the depth ofpenetration of applied electromagnetic energy of material construction,either at room temperature or the operating temperature. This sizedifference depends on the chemical compatibility between the fieldconcentrators and the unit susceptor's materials of construction. Wherethere is little concern for deleterious reaction between the unitsusceptor and field concentrator, then the size of the fieldconcentrator, which, based on its depth of penetration of the materialsof construction, can be 1 to 10 times the depth penetration at theoperating temperature. If there is great concern for deleteriousreaction between the unit susceptor and field concentrator, then thesize of the field concentrator should be such not to promote reaction,200 microns to 4 mm.

Additionally, a barrier coating between the field concentrator and theunit susceptor can be present to prevent deleterious chemical reactionbetween the field concentrator and the unit susceptor. Materials forfield concentrators include materials that can be 1) a thermoluminescentmaterial, 2) a phosphorescent material, 3) an incandescent material, 4)ferroelectric, 5) ferromagnetic, 6) ferrimagnetic, 7) MnO₂, 8) TiO₂, 9)CuO, 10) NiO, 11) Fe₂O₃, 12) Cr₂O₃, 13) Li₂O doped MnO₂, 14) Li₂O dopedCuO, 15) Li₂O doped NiO, 16) CuO—MnO₂—Li₂O complex, 17) CuO—MnO₂, 18)silicide, 19) borides, 20) aluminides, 21) nitrides, 22) carbides, 23)ceramic glazes with metal particles, 24) ceramic glazes withsemiconducting particles, 25) materials that produce thermionicemissions, and 26) thermoelectric materials.

Another aspect of this invention is the production of ozone from unitsusceptors and field concentrators. When the distance (gap) between twoconducting or semiconducting field concentrator becomes close enough tocause a discharge of a spark for the field that is produced by theapplied electromagnetic energy, ozone will be produced. The same type ofdischarge can occur on the surface of unit susceptors that areconstructed of an artificial dielectric material. A spark can occur fromgap between the exposed surfaces of the second phase material in theartificial dielectric, and ozone can be produced. This can occur atelevated temperature and when the volume fraction of the second phasematerial exceeds twenty percent (20%). Also, an electric discharge canoccur between two unit susceptors that contain field concentrators andthe gap between exposed surfaces of second phase material from two unitsusceptors.

Another embodiment of this invention is a heat transfer process. Theinvention embodies the input chemical species flow obtaining heat, orbeing preheated, prior to entering the device for thermal or othermethods of treatment by a heat exchange method that provides heat to theinput chemical species flow from heat that is produced from the sourcefor applied energy. The source can be any device that produces theapplied energy. Such a device generally operates at low efficiencies andproduces heat. This heat transfer process for preheating the inputchemical species flow will decrease the cost of operating such a device.The heat from the tube, or tubes, can be exchanged with the inputchemical species flow. After the input chemical species flow ispreheated with heat from the tube, the input chemical species flow canbe further heated by heat transfer either a) from the cavity walls, b)from a conventional heat exchanger (a recuperator) which is locatedafter the exit end of the device, or c) from both the cavity walls andconventional recuperator.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-section of the device according to the invention in alongitudinal axial direction of the breadth of the device and width ofthe device.

FIG. 2 is the device as in FIG. 1 with thermally insulating layers.

FIG. 3 is a cross-section of the device normal to the direction of Flowwith relationship between the susceptor 9 and the depth of penetrationof the susceptor 14.

FIG. 4 is a flow chart representing a heat transfer process.

FIG. 5 is a 2-dimensional graphical representation of the gas-permeable,macroscopic artificial dielectric susceptor that is constructed ofobjects representing unit susceptors where one type of unit susceptor isprimarily reflective and the other type of unit susceptor is eitherprimarily transparent or partially absorptive.

FIG. 6 is a 2-dimensional graphical representation of the gas-permeable,macroscopic artificial dielectric susceptor which is constructed ofobjects representing unit susceptors that have an interconnected networkof primarily reflective unit susceptors.

FIG. 7 is a unit susceptor that is constructed of an artificialdielectric material.

FIG. 8 illustrates field concentrators on the unit susceptors.

FIG. 9 illustrates field concentrators on the surface of, embedded inthe surface of, and embedded within the unit susceptors.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention is a device that uses a gas-permeable structure for asusceptor of electromagnetic energy to react gases for desired productsor to treat pollutants for producing clean air which can be dischargedinto the environment in accordance with the law of the land. The devicehas a specific cavity geometry, location where the applied energy from asource enters the cavity, a susceptor that is designed by the depth ofpenetration of the susceptor, and a means to scale-up the device forlarger flow rates of an air stream without changing the susceptor'sinteraction with the applied energy or depth of penetration of thesusceptor because the device is designed to increase the size of thedevice by a near linear scale from the location where the appliedelectromagnetic energy enters the cavity and the cavity's geometry.

Another aspect of this invention is a heat transfer process thatincreases the efficiency of the device.

Another aspect of this invention is a gas-permeable, macroscopicartificial dielectric susceptor which uses reflection, scattering andconcentration of the applied electromagnetic energy which is used a) toreact gases for desired products or to treat pollutants for producingclean air which can be discharged into the environment in accordancewith the law of the land, b) to regulate the temperature of the airstream, c) to prevent the device from overheating, d) to preventdeleterious reactions between the materials of construction, e) to heata gas stream, f) to create a device of substantial size for adsorptionand regeneration of gaseous species from a mixture of carbon-containingsusceptor and zeolite-containing susceptors, and g) to produce a desiredratio of a self-limited temperature to power concentration of appliedenergy or energies to perform the desired utility.

Another aspect of this invention is the structure of the unitsusceptors, which can make up the gas-permeable, macroscopic artificialdielectric susceptor.

Another aspect of this invention is the use of field concentrators onunit susceptors to create local electromagnetic fields by interactionwith the applied electromagnetic energy.

The integral parts of the device are the cavity, 1, the inlet opening,2, which is permeable to gases and particulate and provides a means toprevent applied electromagnetic energy from escaping the cavity, theoutlet opening, 3, which is permeable to gases and provides a means toprevent applied electromagnetic energy from escaping the cavity, openingto the cavity, 4, which allows the applied electromagnetic energy toenter the cavity, lenses, 5, which focus or disperse the appliedelectromagnetic energy in the cavity, and if necessary, provide agas-tight seal to prevent gases and particulate from escaping thecavity, applied energy, 6, electromagnetic energy sources, 7,waveguides, 8, and susceptor, 9, which is the suscepting region on thedevice.

Discussion of FIGS. 1, 2 and 3 illustrates the construction of thedevice to react gases for desired products or to treat pollutants forproducing clean air which can be discharged into the environment inaccordance with the law of the land, details the operation for thedevice and discloses, in its broadest sense, the primary embodiment ofthis invention.

FIG. 1 is an axial, longitudinal section of the device that is known inthis invention as the device breadth. In FIG. 1, the geometric axes ofthe device are given by arrows marked W for width and B for breadth. Thedevice has a rectangular cavity, 1, having an inlet opening, 2, wherereactant gases or pollutants enter the cavity. Inlet opening, 2, isdesigned to be permeable to reactant gases, pollutants and particulatein the air stream. The reactant gases, pollutants and particulate entercavity, 1, thought inlet opening, 2, and enter susceptor, 9. As thereactant gases, pollutants and particulate pass through susceptor, 9,either gaseous reactants are converted to products or pollutants andparticulates are converted to clean air which can be discharged into theenvironment in accordance with the law of the land by the necessarytreatment means which are produced from the interaction of appliedelectromagnetic energy, 6, with susceptor, 9. The products and clean airexit cavity, 1, though outlet opening, 3. The interaction betweenapplied energy, 6, and susceptor 9 can provide treatment means either a)by a primarily thermal method having all or a very large amount theapplied electromagnetic energy, 6, being absorbed and producing heat insusceptor, 9, b) by a method having the electromagnetic energy primarilyinteract with the gas reactants, pollutants and particulates without asubstantial quantity of applied energy, 6, absorbed by susceptor, 9,producing heat, c) by a method having a combination of methods a and b,or d) by a method where the combined effects of method c and othersubsequent fluorescent radiation, thermoluminescent radiation,thermionic emission and thermoelectricity assist in treating the gasreactants, pollutants and particulates.

The method of treatment is determined by the interaction of appliedelectromagnetic energy, 6, with the material or materials ofconstruction that make-up the susceptor, 9. The applied electromagneticenergy, 6, can be of more than one frequency, UV, IR, visible andmicrowave. The applied electromagnetic energy, 6, enters cavity, 1,through openings, 4, that are located on opposing sides of the cavity,1, as shown in FIGS. 1, 2 and 3. The applied electromagnetic energy, 6,is generated from electromagnetic sources, 7, travels down waveguides,8, and can pass through lenses, 5, which can be located at cavityopening, 4, then interacts with the susceptor, 9. If lenses, 5, are notneeded for the operating conditions of the device, then the appliedelectromagnetic energy, 6, can just enter cavity, 1, through cavityopenings 4.

The reactant gases, pollutants and particulates enter through inletopening, 2, enter susceptor, 9, for treatment. Turbulence can begenerated by the structure of susceptor, 9, to provide better mixing.The residence time in the device that is required by a specifictreatment method is provided by increasing the breadth of the device,which is inclusive of increasing the breadth of susceptor, 9, andcavity, 1. Additionally energy sources, 7, waveguides, 8, and cavityopenings, 4, can be arranged along the breadth of the device to providethe necessary power of applied energy to the susceptor for treatment.Such additionally energy sources, 7, waveguides, 8, and cavity openingson opposing faces can be arranged by anyone skilled in the art toprovide the optimum conditions. Electronic methods of controllingapplied power and start-up methods can be employed by those skilled inthe art without taking away from the embodiment of this invention. Thisdevice can be employed in operation in a horizontal position and/or in avertical position.

FIG. 2 provides the same view as FIG. 1. FIG. 2 illustrates the locationof thermal insulation, 10, and a thin thermally insulating barrier, 11,that prevents gases, pollutants and particulates from passing throughits boundaries. Thermal insulation, 10, and a thin thermally insulatingbarrier, 11, surround the perimeter of susceptor, 9, in the direction ofthe breadth of the susceptor. Thermal insulation, 10, and thin thermallyinsulating barrier, 11, is constructed of material that is transparentto the applied electromagnetic energy. Material of construction that aretransparent to the applied electromagnetic energy can be high purityalumina, aluminosilicate, MgO, steatite, enstatite, fosterite, nitrides,ceramic porcelain, fused silicate and glass in fiber or foam form. Thepreferred materials structure for thermal insulation, 10, is an aerogel.The thermally insulating layer, 10, and thin thermally insulatingbarrier, 11, are employed to prevent cavity, 1, and waveguides, 8, andenergy sources, 7, from being effected in an adverse manner by heat fromtreatment methods which can cause unwanted thermal expansion, corrosionand deterioration of electronic.

FIG. 3 is a cross-section of the device that is normal to the directionof gas flow from inlet, 2, to outlet, 3. The directional axes for thediscussion of the embodiments of the device are show in FIG. 3 andlabeled W for width and L for length. The device in this inventionembodies the geometric shape of the cavity's cross-section that isnormal to the direction of airflow, 14, in cavity, 1, the location ofopenings, 4, in cavity, 1, the depth of penetration of the susceptor,13, and the width of interaction, 12. The geometric shape of thecavity's cross-section that is normal to the direction of flow, 14, isan irregular shaped polygon that has the largest dimension of the twoparallel sides as it length. The preferred irregular-polygon has four(4) sides and is a rectangle as shown in FIG. 3. This embodiment is notlimit to an irregular-shaped polygon with 4 sides, the irregular-shapedpolygon must have a minimum of four (4) sides.

This invention embodies the geometric shape of the susceptor'scross-sectional area that is normal to the direction of flow ofsusceptor, 9, to have the same geometric shape of the cavity'scross-sectional area that is normal to the direction of flow, 14. Thisinvention embodies the location of the openings, 4, in cavity, 1, to belocated on opposing sides of longest parallel direction of the cavity'scross-section that is normal to the direction of flow, 14, which istermed the length of cross-section, 14.

The susceptor, 9, in this invention embodies a design to have volumetricinteraction with the electromagnetic energy. Susceptor, 9, is designedto have a depth of penetration of the susceptor, 13, by appliedelectromagnetic energy, 6, at the operating temperature that can not beless then one-third (⅓) the width of the of susceptor. This embodieddesign allows for a minimum 50% of the applied electromagnetic energy,6, to be present in each half volume of the susceptor, 9, where the halfvolume of the susceptor is defined by the product of the width ofinteraction, 12, by the length of the susceptor by the breadth of thesusceptor. The width of interaction is equal to one-half of the width ofthe interior dimensions of cavity, 1. The embodied susceptor designallows a) for volumetric interaction between the applied energy, 6, andthe susceptor, 9 and b) for volumetric interaction between appliedenergy, 6, and the reactant gases, pollutants and particulates. Therectangular cavity design does not concentrate energy by the geometry ofthe rectangular cavity, 1, or the rectangular shape of the susceptor.Provided that the susceptor is a homogeneous material, the rectangularshape of the susceptor interacts optically with the appliedelectromagnetic energy, 6, from openings, 4, in cavity, 1, as though thesusceptor was a flat lens. On the other hand, if the geometry of thecavity's cross-sectional area normal to the direction of flow andgeometry of the susceptor's cross-sectional area normal to the directionof flow was circular and the applied energy enters this type of cavityfrom openings that were located around the perimeter of the cavity, thenapplied energy will tend to concentrate in the circular susceptor.

The device, in this invention, embodies the ability to linearly scalethe device for gas streams with larger flow rates without having toredesign the depth of penetration of the susceptor, 13. The linear scaleis accomplished simply by keeping the widths of susceptor, 9, and ofcavity, 1, while extending the lengths of the susceptor, 9, and cavity1. The depth of penetration of the susceptor, 13, and the width ofinteraction, 12, will remain constant. One may have to add more energysources, 7, waveguides, 8, openings, 4, in cavity, 1, along the extendedlength to provide more power to the cavity, but the cost involved ismuch less than redesigning the susceptor's properties that interact withthe applied electromagnetic energy to provide volumetric interactionbetween the applied energy and the susceptor's and cavity's new size andgeometric structure. Additionally, the cost to treat higher flow ratesin the same size cavity as lower flow rates by increasing the power canrequire the use of costly high power tubes that produce theelectromagnetic energy.

Another aspect of the invention, as shown in FIG. 3, is employingwaveguides, 8, that intersect the surfaces of the cavity, 1, at obliqueangles to produce large openings, 4, in cavity, 1, that allows for theapplied electromagnetic energy, 4, to be applied over a larger surfaceof the susceptor. Also, the use of waveguides, 8, allows for the energysource, 7, to be located away from the cavity to lessen any deleteriousinteraction between heat and the energy source, 7.

The dimensions of the cavity, 1, can be designed for the frequency ofthe applied electromagnetic energy and the TE and TM modes of theapplied electromagnetic energy. The size of the cavity may be adjustedto accommodate desired TE and TM modes at certain power levels, whichproduce more uniform heating of the susceptor.

The inlet, 2, and outlet, 3, can prevent the applied electromagneticenergy, 6, from escaping with a perforated article made from areflective artificial dielectric materials, polarizers that are arrangedin a cross-nickels fashion, fermi-cages, attenuators, or undulatingpaths.

The thickness of the wall in cavity, 1, is determined by the skin depthof the material for the applied frequency or frequencies. The thicknessof the wall is a minimum three (3) skin depths of the material for theapplied frequency. When more than one frequency of electromagneticenergy is applied to the cavity, the skin depth of materials isdetermined by the lowest frequency of radiation.

The materials of construction that are selected for the cavity, 1, isdependent on operating temperatures. The materials can be stainlesssteels, aluminum, aluminum alloy, nickel, nickel alloy, inconel,tungsten, tungsten alloys, aluminides, silicides, vanadium alloys,ferritic steel, graphite, molybdenum, titanium, titanium alloys,artificial dielectric materials which are design to reflect incidentradiation, copper alloys, niobium alloys, chromium alloy, inconel,chromyl, alumel, copper/constantine alloys and other high temperaturealloys. For radio frequencies, transparent materials such as aluminaporcelains, zircon porcelains, lithia porcelains, high temperatureporcelains, glasses, alumina, mullite, fused silica, quartz, forsterite,steatite, cordierite, enstatite, BN, AlN, Si₃N₄, oxides and otherpolymers which exhibit low dielectric and conductive losses at theapplied frequencies can be applied.

The applied electromagnetic energy at one or more frequencies can enterthe cavity through openings, 4, in the walls adjacent to the macroscopicsusceptor or be channeled through the cavity to the macroscopicsusceptor from either above, below or passing through transparentthermal insulation adjacent to the side walls. The applied energy canenter through a single or plural openings that either contains insertedbulbs, antenna or tubes, that are either couplers, lenses, slottedwaveguide or zigzag slotted waveguides. The applied energy, 6, can belinearly polarized, circularly polarized or polarized by reflection orscattering. Entering radiation from multiple couples can be polarized insuch a manner to achieve a better distribution of electromagnetic energyin the cavity.

More than one frequency of electromagnetic energy can be propagatedthrough the openings, 4. For waveguides, 8, the cut-off frequency willdetermine the frequencies that can propagate through the waveguide.

When lenses, 5, are employed, optical engineering for the lenses can beused to obtain the desired effect. The radius of curvature of the lensor lenses can be adjusted to concentrate or disperse the electromagneticenergy (convergence and divergence of the applied energy). The lensthickness can be adjusted to eliminate or greatly reduce reflection ofthe energy so that the reflection of the energy back to the radiationsource does not damage the source. Coatings on the lenses can be use toreflect selected wavelengths back into the cavity. Materials for lenses,5, should have high purity (greater than 99% pure) transparent singlecrystals, polycrystalline and amorphous organic and inorganic materialswith low dielectric constants, low dielectric losses such as aluminaporcelains, zircon porcelains, lithia porcelains, high temperatureporcelains, glasses, alumina, mullite, forsterite, steatite, cordierite,enstatite, BN, AlN, Si₃N₄, oxides and other polymers, MgO, fused silica,iodides, bromides, polycarbonate, polypropylene, and quartz. Theporosity of the material can be used to scatter the applied energy intothe cavity. The porosity would be designed for the applied energy.

Waveguides, 8, can either be horns or rectangular, cylindrical, orparabolic shapes. The best waveguide shape is a rectangle thatintercepts the surface of the cavity at oblique angles as shown in FIG.3. The oblique angle increases cross-sectional area of the opening intothe cavity and minimizes the back reflection off the surface of themacroscopic susceptor and/or insulation into the waveguide which wouldbe transmitted back to the radiation source, 7, or diminish the power,6, emanating from the waveguides, 8.

Another embodiment of this invention is a heat transfer process. Theheat transfer process is illustrated by the flow chart in FIG. 4. Theinvention embodies the input chemical species flow obtaining heat, orbeing preheated, prior to entering the device for thermal or othermethods of treatment by a heat exchange method that provides heat to theinput chemical species flow from heat that is produced from the sourcefor applied energy. The source can be a magnetron, a UV lamp, an IR lampor other electronic device that produces the applied energy, 6. Such adevice generally operates at low efficiencies and produces heat. Thisheat transfer process for preheating the input chemical species flowwill decrease the cost of operating such a device. The heat from thetube, or tubes, can be exchange with the input chemical species flow bysuch cooling fins, such as those that are found on commercialmagnetrons, heat pipes, thermoelectric devices, cooling systems thatcirculate a fluid around the tube or lamp and release the heat at aradiator. After the input chemical species flow is preheated with heatfrom the tube, the input chemical species flow can be further heated byheat transfer either a) from the cavity walls, b) from a conventionalheat exchanger (a recuperator) that is located after the exit end of thedevice, or c) from both the cavity walls and conventional recuperator.

Heat exchange with the artificial dielectric device and other devicesthat use electromagnetic energy can allow for increased energyefficiency of the device, as well as to allow for increased energyefficiency to processes outside the device in an industrial process orwithin a manufacturing facility. Increased energy efficiency of thedevice reduces the operating cost of the device, while the increasedenergy efficiency outside the device utilizes heat energy produced bythe device for other applications. These applications can be, but arenot limited to, heating water for washing applications in textileoperations, heating water for pulping operations, preheating air forcombustion in coal-fired electricity generation, preheating air, methaneor both for gas-fired turbine electricity generation, preheating ammoniafor selective non-catalytic reduction (SNCR) of nitrogen oxides (NOx)and selective catalytic reduction (SCR) or nitrogen oxides (NOx) and topreheat methane or other gaseous organics prior to entering a devicewhich catalyzes the methane or other gaseous organic species to higherorder molecules.

The heat exchange process in FIG. 4 can have additional steps. Thesesteps can include additional heat exchange, cooling of the outputchemical species flow prior to heat exchange with either a conventionalheat exchanger, charged air cooler, heat pipes or other device, andmixing input chemical species flow from different heat exchange methodsprior to entering the device which treats the input chemical speciesflow.

Another aspect of this invention is a heat exchange process having thesteps where: step (1) the heat exchange between the source ofelectromagnetic energy and the input chemical species flow or part ofthe input chemical species flow occurs; step (1a) next the inputchemical species flow or part of the input chemical species flow isfurther heated by heat exchange between the exiting hot, output chemicalspecies flow by exchange of heat with either conventional pipe heatexchanger, heat pipes, charged air coolers or other means; step (2) thenthe input chemical species flow or part of the input chemical speciesflow enters the device to be treated; and step (3) output chemicalspecies flow exits the device and exhausts through the heat exchangesystem. The benefits of this method for a heat exchange process is thatthe experimentally measured temperatures of cooling air over magnetrons,at steady-state conditions in this device and under the operatingconditions, provide data that exhibits a temperature change of theambient air after exchanging heat with the magnetron tubes. The initialambient air temperature of approximately 80° F. was raised toapproximately 130° F., providing a change in temperature ofapproximately +50° F. This small, but significant, rise in airtemperature provides cooling for the electromagnetic source, magnetrons.Without this cooling, the magnetrons would overheat, reduce their poweroutput, lessen the lifetime of electronic device or combination thereof.This heat exchange process must be carried out in the order of step (1)then step (1a). This process cannot exchange the order of step (1) andstep (1a) and provide the necessary cooling of the electromagneticsource. If step (1a) was switched with step (1), then the gases leavingthe heat exchange method in step (1a) would be too hot to provide thenecessary heat exchange for cooling the electromagnetic source.

Other experimental data provides support for the order of the steps. Thetemperature of the output chemical species flow, under operatingconditions and prior to exhausting via the heat exchanger in step (1a),was in excess of 842° F. The heat exchange from step (1a) would raisethe temperature of the input gases too great to be effective in coolingthe applied electromagnetic source. Even if the gaseous output chemicalspecies are expanded to reduce the temperature of the output chemicalspecies flow prior to entering the heat exchanger in step (1a), it isdoubtful that an effective heat exchange process and desired massbalance between the input chemical species flow and the output chemicalspecies flow could be obtained.

Another aspect of this invention is a heat exchange process having thesteps where: step (1) the heat exchanges between the source ofelectromagnetic energy and the input chemical species flow or part ofthe input chemical species flow occurs; step (1a) next the inputchemical species flow or part of the input chemical species flow isfurther heated by heat exchange between the exiting hot, output-chemicalspecies flow by exchange of heat with either conventional pipe heatexchanger, heat pipes, charged air coolers or other means; step (2) thenthe input chemical species flow or part of the input chemical speciesflow enters the device to be treated; step (3a) output chemical speciesflow exits the device and the output chemical species flow is cooled;and step (3b) the output chemical species flow exhausts through the heatexchange system. In step (3a) the output chemical species flow can becooled by a variety of means and for a variety of purposes. Cooling instep (3a) can occur by expanding the gaseous output chemical species,using a coil containing fluid species that is in communication withneither the input nor the output chemical species or other methods. Step(3a) provides for the use of lower cost material for the construction ofthe heat exchange devices in step (1a). These materials can be aluminum,aluminum alloys, or other. In addition, step (3a) allows for theapplication of the heat exchange process with the treatment device to beoptimized for economic benefit of an industrial process or manufacturingfacility. Examples of potential economic benefit are: textilesindustry—an economic benefit to cool the output chemical species in step(3a) with fluids that eventually are used to wash textiles with hotwater; coal-fired power plants—combustion air is preheated in step (3a);and gas-fired power plants—methane and combustion air is preheated instep (3a).

Another aspect of this invention is a heat exchange process having thesteps where: step (1b) the heat exchanges between the source ofelectromagnetic energy and part of the input chemical species flowoccurs; step (1c) another part of the input chemical species flow isfurther heated by heat exchange between the exiting hot, output-chemicalspecies flow by exchange of heat with either conventional pipe heatexchanger, heat pipes, charged air coolers or other means; step (1d) allinput chemical species flows are mixed prior to entering the device fortreatment; step (2) then the entire input chemical species flow entersthe device for treatment; and step (3) the output chemical speciesexhausts through the heat exchange system. Step (3a) disclosed in thepreceding paragraph can be added to this heat exchange process ifneeded.

Another embodiment of this invention is a structure of the gas-permeablesusceptor, 9. This invention embodies a macroscopic artificialdielectric structure for the gas-permeable susceptor, 9. The embodiedgas-permeable macroscopic artificial dielectric susceptor can be ahoneycomb structure, foam, or woven fabric filter with a pattern, or astructure consisting of discrete susceptors, which are referred toherein as unit susceptors. This invention embodies the gas-permeable,macroscopic artificial dielectric susceptor to allow for appliedelectromagnetic energy, 6, to penetrate the distance between theprimarily reflective components, whether a discrete susceptor, a coatingpattern or woven pattern structure so the structure does not act as acollection of waveguides with cut-off frequencies that prevents theapplied energy, 6, from penetrating the width of interaction, 12. Thegas-permeable, macroscopic artificial dielectric susceptor embodies a)an article constructed of a material where the article has a coatingapplied in a specific pattern to create a macroscopic artificialdielectric structure from the coating and the article, b) a wovenstructure that contains two or more different materials as threads (oryarns) which woven together to form a macroscopic artificial dielectricstructure, or c) a structure that consists of a mixture of discretesuscepting articles where the mixture contains discrete articles thathave different dielectric properties and surround each other to form amacroscopic artificial dielectric structure.

When the embodied invention, the gas-permeable macroscopic artificialdielectric structure, has an article which is a honeycomb structureconstructed of a material, some of the cell walls of the honeycomb canbe coated with materials that have different dielectric properties toproduce a macroscopic artificial dielectric. The pattern of cells withcoated walls are arranged in the honeycomb so that the appliedelectromagnetic energy and energies penetrate the suscepting structureand either heat the susceptor or scatter the energy for interaction withthe gases/particulate in the air stream. The pattern of the cell wallsattenuate the applied electromagnetic energy by either a) partially orcompletely by absorbing the applied energy, producing fluorescentradiation to heat the remaining parts of the susceptor and the airstream or b) partially or completely scattering applied energy toconcentrate the applied energy for interaction with the air stream or toheat the remaining volume of the susceptor. Also, the embodiedmacroscopic artificial dielectric can be made from the honeycombstructure by filling some of the cells with another material.Additionally, the invention embodies 1) a large honeycombed-shaped,macroscopic artificial dielectric structure that is constructed fromsmaller discrete susceptor articles that are small honeycombed shapedarticles that have differing dielectric properties and/or conductivityor 2) smaller discrete susceptor articles that are honeycombed-shapedthat have the same dielectric property and are cemented together with amaterial which has different dielectric properties and/or conductivity.This invention also embodies the same or similar methods used to createhoneycombed-shaped macroscopic artificial dielectrics to be employed tocreate macroscopic artificial dielectrics out of foams and weaves.

When the embodied macroscopic artificial dielectric susceptor isdesigned as a structure that consists of unit susceptors, susceptors canbe designed for complex interaction with the applied energy or energiesas previously described in Example Three. Potentially, each unitsusceptor can have separate characteristics for absorption,transmission, scattering and reflection of 1) applied electromagneticenergy or energies, 2) subsequent fluorescent radiation produced fromthe applied electromagnetic energy or energies, and 3) the subsequentradiation from heat resulting from the dielectric loss within eachindividual susceptor. The separate characteristics of absorption,transmission, scattering and reflection of a unit susceptor embodied inthis invention are controlled by the unit susceptor's length, thickness,shape, composite materials structure, material selection, porosity, poresizes, temperature dependence of the complex dielectric constant andthermal conductivity.

FIG. 5 describes the structure of the macroscopic artificial dielectricsusceptor, 15, by using a two-dimension array of squares that representunit susceptors. Although the optical properties of each unit susceptorwithin the embodied macroscopic artificial dielectric susceptorstructure, 15, can be independent, the embodied structure of themacroscopic artificial dielectric susceptor, 15, will dictate theinteraction of the macroscopic susceptor with the appliedelectromagnetic energy, 6. The structure of the macroscopic artificialdielectric susceptor will be described with the unit susceptors that areprimarily reflective, 16. This invention, the gas-permeable, macroscopicartificial dielectric susceptor, 15, embodies the principle ofreflection to provide diffuse reflection, scattering, as means forallowing the applied energy, 6, to penetrate the width of interaction,12, in susceptor, 9, to volumetrically interact with susceptor, 9, toproduce the desired method of treatment to react gases for desiredproducts or to treat pollutants for producing clean air which can bedischarged into the environment in accordance with the law of the land.

The reflectivity of the embodied macroscopic artificial dielectricsusceptor, 15, is controlled by the volume and interconnectivity of theunit susceptors, 16, which are the primarily reflective unit susceptorsin the macroscopic susceptor. The primarily reflective unit susceptors,16, are defined as being the unit susceptors to which are primarilyreflective to the applied energy, 6, or energies. The gas-permeable,macroscopic artificial dielectric susceptor has the primarily reflectiveunit susceptors, 16, surrounded by unit susceptors, 17, that are eitherprimarily transparent or partially absorptive of the applied energy orenergies. The primarily reflective unit susceptors, 16, scatter theapplied energy, 6, within susceptor, 9, concentrating the applied energyto interact with either a) the primarily transparent or partiallyabsorptive unit susceptors, 17 or b) the reactant gases, pollutants orparticulates.

As the volume of the primarily reflective unit susceptors, 16, increasesin the gas-permeable, macroscopic artificial dielectric susceptor, 15, adegree of interconnectivity of the primarily reflective unit susceptors,16, will occur, forming an interconnective network within thegas-permeable, macroscopic artificial dielectric susceptor, 15, as shownin FIG. 6. The degree or amount of interconnectivity will depend on thesize and shape of the primarily reflective unit susceptors, 16. Theability of the applied energy, 6, or energies to penetrate themacroscopic artificial dielectric susceptor, 15, 9, will depend not onlyon the volume of the primarily reflective unit susceptor, 16, but alsoon the degree and amount of interconnectivity. When the degree ofinterconnectivity of the primarily reflective unit susceptors, 16,throughout the entire gas-permeable macroscopic artificial dielectricsusceptor, 15, 9, is such that maximum distance between theinterconnected network, 18, of the primarily reflective unit susceptors,16, does not allow for applied energy, 6, to penetrate or the longestwavelength of the applied energies, 6, to penetrate, the gas-permeablemacroscopic artificial dielectric susceptor, 9, 15, itself, will becomeprimarily reflective to either a) the applied electromagnetic energy orb) the longest wavelength of the applied energies, and volumetricinteraction between the applied energy, 6, with susceptor, 9 will notoccur. The volume of susceptor, 9, given by the production width ofinteraction, 12, by the length of the susceptor by the breadth of thesusceptor will not have 50% of the applied electromagnetic energydisturbed volumetrically within the volume.

This invention embodies a gas permeable susceptor with macroscopicartificial dielectric structure, which allows for the appliedelectromagnetic energy, 6, to be able to penetrate the distance, 18,between primarily reflective unit susceptors, 16, allowing forvolumetric interaction within susceptor, 9. The embodiments of thisinvention can be applied to honeycomb structures, weaves and foams whenreflective coating are applied to the structure or the structure areconstructed of smaller pieces that are primarily reflective susceptingunits.

The invention embodies a high degree of interconnectivity of primarilyreflective unit susceptors, 16. A high degree of interconnectivity canbe beneficial in some instances. This invention embodies the use ofclusters of primarily reflective unit susceptors, 16, to be distributedabout the macroscopic artificial susceptor to promote scattering.Primarily reflective unit susceptors can be aggregated to form shapesand boundaries that reflect one or more wavelengths of the appliedenergy or energies.

This invention embodies a macroscopic artificial dielectric structurefor the gas-permeable susceptor, 9, where the volume fraction andinterconnectivity of the reflective unit susceptors, 16, surroundingpartially absorbing or primarily transparent unit susceptors, 17, as ameans to design specific macroscopic artificial dielectric structures a)for resonant cavities that are based upon the wavelength of the appliedenergy in the susceptor, b) for scattering energy for interaction withgas or particulate species, c) that concentrate energy at fieldconcentrators which are located on other unit susceptors, d) thatconcentrate energy within the susceptor for increase reactivity betweenthe gas stream and the fluorescent radiation, e) that have the primarilyreflective unit susceptors arranged in such a manner to produce a largespiral, helical or other shape with the macroscopic susceptor, f) thatact as shielding to prevent the applied electromagnetic from enteringmaterial inside the cavity for thermal insulation, g) that preventleakage outside the cavity by the applied energy, h) that reflectapplied energy to other regions of the artificial dielectric to provideeither higher temperatures or increased energy for reaction ordestruction of gaseous/particulate species, and i) that regulate thetemperature of the gas-stream.

This invention also embodies a gas-permeable susceptor, 9, with amacroscopic artificial dielectric structure, which uses reflection,scattering and concentration of the applied electromagnetic energy as ameans a) to react gases for desired products or to treat pollutants forproducing clean air which can be discharged into the environment inaccordance with the law of the land, b) to regulated the temperature ofthe air stream, c) to prevent the device from overheating, d) to preventdeleterious reactions between the materials of construction, e) to heata gas stream, f) to create a device of substantial size for adsorptionand regeneration of gaseous species from a mixture of carbon-containingsusceptor and zeolite-containing susceptors, and g) to produce a desiredratio of a self-limited temperature to power concentration of appliedenergy or energies to perform the desired utility.

This invention embodies primarily of the unit susceptors, 16, that areproduced from metallic or intermetallic materials species at roomtemperature or materials such as semiconductors, ferroelectrics,ferromagnetics, antiferroelectrics, and antiferromagnetics that becomereflective at elevated temperatures. The embodied unit susceptor'smaterials that produce reflection are either a) homogeneous materials,b) composite materials having a second phase material in a matrix thatis partially absorptive to applied electromagnetic energy where thevolume fraction of the second phase materials can be used to control theamount of reflection of a unit susceptor, or c) a coating on a unitsusceptor. This invention also embodies the length, width and shape ofthe primarily reflective unit susceptors, 16, and the distance betweenreflective unit susceptors, 18, to control the reflectivity of thegas-permeable, macroscopic artificial dielectric susceptor.

The shape of the unit susceptor can be designed for reflection. Theinvention embodies the shape of the unit susceptor that are eitherchiral, spire-like, helical, rod-like, acicular, spherical, ellipsoidal,disc-shaped, needle-like, plate-like, irregular-shaped or the shape ofspaghetti twist in Muller's Spaghetti and Creamette brand. Thisinvention embodies the shape of the unit susceptor to produce turbulencein the airflow, thus providing for mixing of reactants in the gaseous orliquid stream. The shape and size of the susceptor can be used to gradethe pore size of the susceptor to accommodate the expansion of gas dueto passing through the hot zone.

Another embodiment of this invention is unit susceptor, 19, that isillustrated in FIG. 7. Unit susceptors, 19, can make up thegas-permeable, macroscopic artificial dielectric susceptor, 15. The unitsusceptor's, 19, shape can be chiral, spire-like, helical, rod-like,acicular, spherical, ellipsoidal, disc-shaped, irregular-shape,plate-like, needle-like or the shape of a Muller's spaghetti twist(rotini). The susceptor, 19, can be an artificial dielectric material,made from a homogeneous material or have a coating on the unit susceptorthat is either made from a homogeneous material or artificial dielectricmaterial. The length of unit susceptor, 19, should be greater than 0.25inches and the width should be greater than {fraction (1/16)}th of aninch.

The absorption, transmission, reflection, scattering and the complexdielectric constant of unit susceptors, 19, can be controlled by usingartificial dielectric materials. The structure of a unit susceptor, 19,made from an artificial dielectric material is shown FIG. 7. The unitsusceptor, 19, has a matrix material, 20, which contains a second phasematerial, 21 or third phase material, 12. The purpose of using anartificial dielectric material for a unit susceptor, 19, is to produceprimarily reflective unit susceptors, 16. The reflectivity of theprimarily unit susceptors, 16, can be controlled by size, volumefraction and shape of the second phase material, 21 or third phasematerial, 12. A volume fraction of the second phase material over 50%can produce an interconnected network of the second phase materials,which has a reflectivity that behaves the same as higher volumefractions. The shape of the second phase can be chiral, spire-like,helical, rod-like, acicular, spherical, ellipsoidal, disc-shaped,irregular-shape, plate-like or needle-like. A size range of the secondphase, 21, which is from the group of materials known as semiconductors,conductors, ferromagnetics, ferroelectrics, ferrimagnetics andantiferroelectrics is embodied in this invention.

The size-range which is embodied in this invention for the second phaseis a particle size range that is −325 U.S. Mesh Sieve Size or less(equivalent to sizes less than 46 microns). The embodied small particlesize range is used because these particle sizes will rapidly absorbelectromagnetic energy, elevating the temperature of the particles' veryhigh temperature where the particles' material will become veryconductive and/or exceed the Curie temperature, rendering the unitsusceptor to be reflective. Another embodiment of this invention is thatthe thermal expansion mismatch between the second phase material, 21,and the matrix, 20, be less than 15%, in order to prevent the unitsusceptor, 19, from becoming friable. Another embodiment of thisinvention is a method to reduce the thermal expansion mismatch by theunit susceptor's second phase material, 21, being the same crystallinestructure and base material as the matrix material, 20, however thesecond phase's material, 21, is doped on the lattice structure with acation or anion to increase the electrical conductivity of the secondphase's material while producing a very low thermal expansion mismatchbetween the matrix, 20, and the second phase material, 21. Anotherembodiment of this invention is to have the particle size of the secondphase material, 21, be in the size range of between 200 microns and 3 mmin the unit susceptor, 19, when strong potential for deleteriouschemical reaction between the matrix, 20, and the second phase material,21, in unit susceptor, 19.

Additionally, the composite materials for unit susceptors can use acombination of materials in such a fashion where the selected materialsproduce thermoluminescent, incandescent and phosphorescent radiation.

Another embodiment of this invention is the use of field concentrators,22, on unit susceptors, 19, as illustrated in FIG. 8. This inventionembodies the use of field concentrators, 22, to concentrate theelectromagnetic field locally so a high intensity electromagnetic fieldis available to interact with gaseous/particulate species to eitherdrive chemical reaction, enhance the reaction between chemical speciesor to treat pollutants. This invention embodies materials ofconstruction of field concentrators, 22, that are a) conductors, b)semi-conductors, c) materials with a Curie Point, d) ionic-conductingceramic, e) composite materials from a and c, f) composite materialsfrom b and c, g) composite materials from a and d, and h) compositematerials from b and d. This invention embodies the shape of fieldconcentrators, 22, to be selected from shapes that are chiral,spire-like, helical, rod-like, acicular, spherical, ellipsoidal,disc-shaped, irregular-shape, plate-like, needle-like or have a shapethat has sharp-pointed-gear-like teeth.

This invention embodies a size range for the field concentrators, 22,that is used to prevent deleterious chemical reaction between the fieldconcentrators, 22, and unit susceptor, 19. The size of the fieldconcentrators can be one to 10 times the depth of penetration of appliedelectromagnetic energy of materials of construction, either at roomtemperature or the operating temperature. This size difference dependson the chemical compatibility between the field concentrators and theunit susceptor's materials of construction. Where there is littleconcern for deleterious reaction between the unit susceptor and fieldconcentrator, then the size of the field concentrator, which, based onits depth of penetration of the materials of construction, can be 1 to10 times the depth penetration at the operating temperature. If there isgreat concern for deleterious reaction between the unit susceptor andfield concentrator, then the size of the field concentrator should besuch not to promote reaction, 200 microns to 4 mm.

Additionally, this invention embodies the use of a barrier coating, 23,between the field concentrators, 22, and the unit susceptor, 19, toprevent deleterious chemical reaction between the field concentrator andthe unit susceptor. Also, this invention embodies materials ofconstruction for field concentrators, 22, including 1) athermoluminescent material, 2) a phosphorescent material, 3) anincandescent material, 4) ferroelectric, 5) ferromagnetic, 6)ferrimagnetic, 7) MnO₂, 8) TiO₂, 9) CuO, 10) NiO, 11) Fe₂O₃, 12) Cr₂O₃,13) Li₂O doped MnO₂, 14) Li₂O doped CuO, 15) Li₂O doped NiO, 16)CuO—MnO₂—Li₂O complex, 17) CuO—MnO₂, 18) silicide, 19) borides, 20)aluminides, 21) nitrides, 22) carbides, 23) ceramic glazes with metalparticles, 24) ceramic glazes with semi-conducting particles, 25)materials that produce thermionic emissions, and 26) thermoelectricmaterials.

This invention embodies the production of ozone from fieldconcentrators, 22, on unit susceptor, 19 as shown in FIG. 8. When thedistance (gap), 23, between two field concentrators, 22, which are madefrom materials which are conducting or semi-conducting are at such adistance, the applied electromagnetic field, 6, can cause a discharge ofa spark from localized fields that are produced by the appliedelectromagnetic energy, producing ozone. The invention also embodies theproduction of ozone on the surfaces of unit susceptors, 19, which areconstructed of artificial dielectric material as shown in FIG. 7. Aspark can occur from a gap, 24, between the exposed surfaces of thesecond phase material, 21, and ozone can be produced. This inventionembodies the production of ozone that can occur at elevated temperaturesand when the volume fraction of the second phase material, 21, exceedstwenty percent (20%). Also, this invention embodies the production ofozone from electric discharges that can occur a) between two unitsusceptors, 19, in close proximity that contain field concentrators, 22,b) between exposed surfaces of second phase material, 21, from two unitsusceptors in close proximity, and c) between two unit susceptors, 19,where one unit susceptor, 19, contains a field concentrator, 22, and theone unit susceptor contains an exposed surface of a second phasematerial, 21.

The above description sets forth the best mode of the invention as knownto the inventor at this time, and is for illustrative purposes only, asone skilled in the art will be able to make modifications to thisprocess without departing from the spirit and scope of the invention andits equivalents as set forth in the appended claims.

Field Concentrators

This invention embodies different locations for field concentrators in asusceptor. The susceptor can be a macroscopic susceptor, 15, or a unitsusceptor, 19. As shown in FIG. 9, a field concentrator can be locatedon the surface of a susceptor, 22, embedded in a surface of susceptor,22 a, or embedded in the matrix, 22 b, of a susceptor. A susceptor canhave a combination of these locations of field concentrators to generatelocal electric fields. When a field concentrator, 22 b, is embedded inthe susceptor, the matrix, 20, would be made of a material that hasenough permittivity and permeability to the applied electromagneticenergy and enough permittivity and permeability that allows forproducing a local field about the surface of the susceptor from embeddedfield concentrator, 22 b. A susceptor can contain a plurality of fieldconcentrators. As shown in FIG. 7, the non-matrix material, 21, that isembedded in the surface of susceptor, 19, can behave as fieldconcentrators as mentioned earlier to produce ozone. Additionally, whenthe field concentrator is on the surface, 22, or embedded in the surfaceof a susceptor, 22 a, the susceptor can be a homogeneous material, not acomposite. The homogeneous material of the susceptor can either bereflective to the applied electromagnetic energy, be an insulator, be amaterial that has a Curie temperature, a material that has dielectriclosses or a material that absorb at least a portion of the appliedelectromagnetic energy.

Another aspect of this embodiment is that reflective non-matrixmaterial, 21 b, can be used to reflect applied electromagnetic energy toa field concentrator to increase the local electric field. As shown inFIG. 9, the reflective non-matrix material, 21 b, is a material that isprimarily reflective to the applied electromagnetic energy at roomtemperature or a material that becomes reflective to the appliedelectromagnetic energy at temperatures greater than room temperature.

The invention also is a method of locally concentrating an appliedelectric field to promote chemical reaction having a dispersion ofindividual field concentrators at a location selected from the groupconsisting of on the surface of a substrate, embedded on a substrate,and embedded on the surface of a substrate, wherein the individual fieldconcentrators consists of shaped material and the shape and material arecapable of producing a locally concentrated electric field in thevicinity of the field concentrator from interaction between the fieldconcentrator and the applied electric field.

The shape of an individual field concentrator can be selected from thegroup consisting of chiral shape, spire-like shape, shape cylindricalshape, tubular shape, helical shape, rod-like shape, plate-like shape,acicular shape, spherical shape, ellipsoidal shape, disc-shaped shape,irregular-shaped shape, plate-like shape, needle-like shape, twistshape, and a shape like a pasta rotini twist.

The size of an individual field concentrator preferably is between onenanometer and one meter.

The material for an individual field concentrator preferably is selectedfrom the group of materials consisting of a material that is capable ofcreating an electric field, a chalcogenide, a metal alloy, asolid-solution crystalline material, a Fe-based alloy, a precious metalalloy, an artificial dielectric, an artificial dielectric material wherethe volume fraction of the non-matrix species is less that 50 volumepercent, an artificial dielectric material where the volume fraction ofthe non-matrix species is equal to or greater than 50 volume percent, amaterial that produces thermionic emissions, a material that isthermoelectric, a cermet, a composite material, an organic polymericmatrix composite, a ceramic matrix composite, a metal matrix composite,copolymer, a Co-alloy, a Ni-alloy, antiferromagnetic, antiferroelectric,paramagnetic, a material with a Curie temperature, glassy, metallic,ferrimagnetic, ferroelectric, ferromagnetic, semiconducting, conducting,a solid-state ionic conductor, a non-stoichiometric carbide, anon-stoichiometric oxide, an oxycarbide, an oxynitride, a carbonitride,an intermetallic, a hydroxide, thermoluminescent, fluorescent, a boride,a material with low dielectric constant and low dielectric losses, amaterial with a high dielectric constant and low dielectric losses, Fe,Co, Ni, a silicide, a nitride, an aluminide, a material with a highdielectric constant and high dielectric losses, a material with a highdielectric constant and moderate dielectric losses, a carbide, an oxide,anatase, a sulfide, a sulfate, carbonate, FeO, CuO Cu₂O, MnO₂ Mn₂O₅,NiO, Fe₂O₃, Fe₃O₄, Li₂O—NiO, TiO₂ doped with a divalent cation, TiO₂doped with a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, CuO—MnO₂,Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y),TiC_(1-x), TiO₂, a non-stoichiometric titanium oxide, TiO, Ti₂O₃, anon-stoichiometric zirconia oxide, anatase, beta″-alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na,Li)-beta-alumina, acarbon, a graphite, ZnO, CuS, FeS, CoO, a calcium aluminate, char, Ni,Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), ap-type material, an n-type material, a cation-doped p-type dominatematerial, an anion-doped p-type dominate materials, a cation-dopedn-type dominate material, an anion-doped n-type material, a metal, anamorphous material, and a non-stoichiometric nitride.

A coating also can be placed between the substrate and fieldconcentrator wherein the utility of coating is selected from the groupof utility consisting of a coating containing a catalyst for catalysis,a coating to prevent deleterious reaction between the field concentratorand the susceptor's materials of construction, a coating that is used toadhere the field concentrator to the susceptor, a coating to provideelectrical insulation between the field concentrator and the susceptor'smaterials of construction, a coating to create a strong local electricfield where the coating's material has a high dielectric constant withlow dielectric losses, a coating to create a strong local electric fieldwhere the coating's material has a moderate dielectric constant anddielectric losses, a coating that is a semiconductor where the coatingheats due to the field concentration of the field concentrator, andcombinations thereof.

The substrate preferably is constructed of low-loss dielectric materialselected from the group of materials consisting of alumina,aluminosilicate ceramic, magnesium aluminosilicate ceramic, magnesiumsilicate, calcium silicate, calcium aluminosilicate, clay, zeolite,magnesium oxide, sialon, oxynitride, inorganic glass, organic glass,organic polymer, crystalline organic polymer, a polymer composite,cordierite, enstatite, forsterite, steatite, nitride, porcelain,high-temperature porcelain, a glass ceramic, a phase separated glass, alithium-aluminosilicate, Teflon, a organic copolymer, polycarbonate,polypropylene, polystyrene, polyethylene, polyester,polytetrafluoroethylene, and combination thereof.

The substrate also can be constructed of materials selected from thegroup of materials consisting of a material that is amorphous,polycrystalline, antiferromagnetic, antiferroelectric, paramagnetic, anartificial dielectric, an artificial dielectric material where thevolume fraction of the non-matrix species is less that 50 volumepercent, an artificial dielectric material where the volume fraction ofthe non-matrix species is equal to or greater than 50 volume percent, amaterial that produces thermionic emissions, a material that isthermoelectric, a cermet, a composite, a material with a Curietemperature, glassy, metallic, ferrimagnetic, ferroelectric,thermochromatic, photochromatic, ferromagnetic, semiconducting,conducting, a solid-state ionic conductor, a non-stoichiometric carbide,a non-stoichiometric oxide, an oxycarbide, an oxynitride, acarbonitride, an intermetallic, a hydroxide, a non-stoichiometricnitride, thermoluminescent, a non-stoichiometric Ilmenitic structure,fluorescent, a boride, a material with low dielectric constant and lowdielectric losses, a material with a high dielectric constant and lowdielectric losses, an oxide, a silicide, a nitride, an aluminide, amaterial with a high dielectric constant and high dielectric losses, amaterial with a high dielectric constant and moderate dielectric losses,a carbide, an oxide, anatase, a sulfide, a sulfate, a carbonate, a glassceramic, a phase separated glass, an ionic conductor, a catalyst, amaterial derived by processing a clay mineral with heat to a temperatureand for time period above the temperature that the water ofcrystallization is removed and below a temperature and for time periodthat prevent complete transformation of the clay material tononreversible crystalline and/or glass phases, a material derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to non-reversible crystalline and/or glass, a materialderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, a material derived by processingBrucite with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe Brucite material to non-reversible crystalline material, a materialderived by processing a Gibbsite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline material, and combinations thereof.

The preferred clay mineral is selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite, and combinations thereof.

The distance between any two field concentrators prevents the formationof a spark.

The field concentration cam be used for the function selected from thegroup of functions consisting of to drive chemical reactions, to assistin chemical reactions, to drive polymerization, to assist inpolymerization, to assist in catalysis, oglomerization, or combinationthereof, wherein the reaction occurs in physical phases of matter fromthe group consisting of a plasma, gas, solid, liquid, a fluid containingparticulates, and combinations thereof.

The size of an individual field concentrator preferably is less than 20times the depth of penetration of at least one wavelength of appliedelectromagnetic energy in the material that the individual fieldconcentrator is constructed of.

The field concentration preferably has utility that is selected from thegroup of utility that reforms a hydrocarbon, causes polymerization,reduces nitrogen oxides to nitrogen (N₂), reduces NO to nitrogen (N₂),reduces NO₂ to NO, reduces NO₂ to nitrogen (N₂), reduces SO_(x) tosulfur (S), reduces SO₃ to SO₂, reduces SO₄ to SO₂, reduces SO₃ to SO₂,produces chemical synthesis, allows for sterilization, produces crackingof a hydrocarbon, decreases the activation energy of a chemical process,oxidizes volatile organic compound to carbon dioxide and water, oxidizescarbon monoxide to carbon dioxide, synthesizes pharmaceuticals, reducesNOx in the presence of hydrocarbons, synthesizes biodiesel, reforms ahydrocarbon with a hydrogen donor species in the presence of H₂O,reforms a hydrocarbon with methane in the presence of H₂O, reforms ahydrocarbon in the presence of methane, water and carbon dioxide,reforms a hydrocarbon in the presence of methane, water, hydrogen andcarbon dioxide, reforms a hydrocarbon in the presence of hydrogen andmethane, polymerizes a hydrocarbon in the presence of metal halides,reduces nitrogen oxides in the presence of ammonia, reducesnitrogen-oxides in the presence of ammonium-containing compounds, treatspollutants to form clean air which can be discharged into theenvironment in accordance to the law of the land, produces oxidativebond cleavage of a hydrocarbon and produces non-oxidative bond cleavageof a hydrocarbon, wherein the reaction occurs in physical phases ofmatter from the group consisting of a plasma, gas, solid, liquid, afluid containing particulates, and combinations thereof.

The method of field concentration is used in an atmosphere preferablyselected from the group of atmosphere consisting of a reducingatmosphere, an oxidizing atmosphere, an atmosphere at one atmosphere ofpressure, an atmosphere at less than one atmosphere of pressure, anatmosphere at greater than one atmosphere of pressure, and combinationsthereof.

The field concentrator's electronic properties preferably are selectedfrom the group consisting of a p-type material, an n-type material, acation-doped p-type dominate material, an anion-doped p-type dominatematerials, a cation-doped n-type dominate material, an anion-dopedn-type dominate material, and combinations thereof.

The method electromagnetic properties of the field concentrator'smaterials preferably is control by a crystalline defect. The defectpreferably is selected from the group of consisting of an intrinsicdefect, an extrinsic defect, defect from cation substitution, a defectfrom anion substitution, and combinations thereof.

The operating temperature of the method of field concentrationpreferably is selected from the group of operating conditions consistingof a temperature which is above the Curie temperature of all the fieldconcentrators' materials, a temperature which is below the Curietemperature of all the field concentrators' materials, a temperaturewhich is above Curie temperature of the non-matrix material only, atemperature which is above the Curie temperature of the matrix materialonly, a temperature which is above the Curie temperature of all thesusceptor's materials causing increased absorption, a temperature whichis above the Curie temperature of the non-matrix causing increasedabsorption, a temperature which is above the Curie temperature of thematrix causing increased absorption, a temperature above the thermalrunaway temperature (critical temperature) of at least one of theconstituent phases, a temperature which is below the thermal runawaytemperature (critical temperature) of all the constituent phases, atemperature which is below the activation temperature of the intrinsicdielectric conduction species of all the phases present, a temperaturewhich is above the activation temperature of at least one intrinsicdielectric conducting species of all constituent phases, a temperaturewhich is below the activation temperature of all extrinsic dielectricconducting species, a temperature which is above the activationtemperature of at least one extrinsic dielectric conducting species ofall the constituent phases, and combinations thereof.

The field concentrator preferably is of a size that is designed tolessen any deleterious chemical reaction between the materials ofconstruction of the electromagnetic susceptor and the materials ofconstruction of the field concentrator.

The field concentrator also may further comprise a catalyst.

The applied electromagnetic energy is applied in the form of continuousenergy, pulsed energy or combination thereof.

The method substrate also can be permeable to a chemical species flow.

An illustrative chemical reaction is the production of ozone frominteraction between a field concentrator and applied electromagneticenergy by having two or more field concentrators on a substrateconstructed of a low-loss dielectric material having a distance betweeneach field concentrator such that a spark is capable of being producedapplying electromagnetic energy to the substrate that contains saidfield concentrators causing a spark discharge while passing a chemicalspecies flow containing oxygen over said substrate.

A second illustrative chemical reaction is the production of ozone frominteraction between a non-matrix material and applied electromagneticenergy by exposing a composite substrate to electromagnetic energy inwhich a portion of the non-matrix material is embedded in the surface ofa susceptor and is exposed above the surface of a susceptor having amatrix constructed of a low-loss and low dielectric constant material,and applying electromagnetic energy to the substrate causing a sparkdischarge while passing a chemical species flow containing oxygen ofsaid substrate.

The volume fraction of the non-matrix material is greater than 0% andpreferably greater than 20%.

Coatings

The invention also is a coated susceptor of electromagnetic energy forchemical processing comprising:

-   -   a matrix material that surrounds a non-matrix material that is        made from a material that is different from the matrix material,        wherein the matrix material is constructed of material having        lower dielectric losses compared to the non-matrix material,        wherein:    -   a. the non-matrix material initially absorbs electromagnetic        energy applied to the electromagnetic susceptor to a greater        extent than the matrix material;    -   b. the non-matrix material produces subsequent heat in the        matrix material; and    -   c. the surface of the susceptor is coated with a material that        interacts with applied electromagnetic energy of at least one        frequency and initially absorbs electromagnetic energy and        produces heat.

The non-matrix material also can produce reflection.

The form of said coating preferably is selected from the groupconsisting of a full coating on all susceptor surfaces, a full coatingon a surface, a partial coating on a surface, a partial coating on allsusceptor surfaces, a coating with a specific pattern, a coatingcontaining a homogeneous material, a coating containing a compositematerial, a partial coating containing a more than one material, apatterned coating containing more than one material, a coatingcontaining multiple layers of different material, and combinationsthereof.

The weight fraction of said non-matrix material preferably is greaterthan 0.00001 weight percent and less than 50 weight percent. The weightfraction of said non-matrix material preferably is greater than 50weight percent and less 99.9 weight percent.

The coating preferably has optical dielectric properties in relation tothe applied electromagnetic energy selected from the group consisting oftransparent, reflective, scattering, absorptive, and combinationsthereof.

The coating can provide a utility to effect a physical property of saidsusceptor selected from the group consisting of mechanical properties,thermal properties, optical properties of the non-matrix material,optical properties of the susceptor, absorption of electromagneticenergy, reflection of electromagnetic energy, transmission ofelectromagnetic energy, scattering of electromagnetic energy,electromagnetic properties, corrosive properties, wear properties,piezoelectric properties, dielectric properties, magnetic properties,electric properties, susceptibility to the applied electromagneticenergy, susceptibility to the fluorescent electromagnetic energy,conductivity, controlling the chemical compatibility between thenon-matrix material and the matrix material, regulating the temperatureof said susceptor, regulating the temperature of a process, regulatingthe amount of electromagnetic energy available for chemical process,regulating the amount of electromagnetic energy available for a physicalprocess, and combinations thereof.

The physical properties often are controlled by the thickness of thecoating.

The coated susceptor can be used in an atmosphere selected from thegroup consisting of a reducing atmosphere, an oxidizing atmosphere, anatmosphere at one atmosphere of pressure, an atmosphere at less than oneatmosphere of pressure, an atmosphere at greater than one atmosphere ofpressure, and combinations thereof.

The coating can be constructed of a material selected from the groupconsisting of metallic, amorphous, polycrystalline, antiferromagnetic,antiferroelectric, paramagnetic, a material with a Curie temperature,glassy, metallic, ferrimagnetic, ferroelectric, ferromagnetic,semiconducting, conducting, a solid-state ionic conductor, anon-stoichiometric carbide, a non-stoichiometric oxide, an oxycarbide, amaterial that produces thermionic emissions, a material that isthermoelectric, a cermet, a ceramic glaze with metal particles, anoxynitride, a carbonitride, an intermetallic, a hydroxide, anon-stoichiometric nitride, thermoluminescent, a composite material, anorganic polymeric matrix composite, a ceramic matrix composite, a metalmatrix composite, a crystalline form of silica, fused silica, quartz, aorganic copolymer, an amorphous organic polymer, a crystalline organicpolymer, polycarbonate, polypropylene, polystyrene, polyethylene,polyester, polytetrafluoroethylene, a non-stoichiometric Ilmeniticstructure, fluorescent, an artificial dielectric material, an artificialdielectric material where the volume fraction of the non-matrix speciesis less that 50 volume percent, an artificial dielectric material wherethe volume fraction of the non-matrix species is equal to or greaterthan 50 volume percent, a boride, a material with low dielectricconstant and low dielectric losses, a material with a high dielectricconstant and low dielectric losses, a silicide, a nitride, an aluminide,a material with a high dielectric constant and high dielectric losses, amaterial with a high dielectric constant and moderate dielectric losses,a carbide, an oxide, anatase, a sulfide, a sulfate, a crystalline formof silica, a carbonate, a glass ceramic, photochromatic,thermochromatic, a phase separated glass, an ionic conductor, a materialderived by processing a clay mineral with heat to a temperature and fortime period above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline and/or glass phases, a material derived by processing talcwith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the talcmaterial to non-reversible crystalline and/or glass, a material derivedby processing a zeolite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the zeolite material to non-reversible crystallineand/or glass phases, a material derived by processing Brucite with heatto a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the Brucite material tonon-reversible crystalline material, and a material derived byprocessing a Gibbsite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the clay material to nonreversible crystallinematerial or combination thereof.

The clay mineral preferably selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite and combinations thereof.

The coating can be constructed of a material selected from the groupconsisting of FeO, CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂,Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y),TiC_(1-x), TiO₂, non-stoichiometric titanium oxide, Li₂O—NiO, TiO₂ dopedwith a divalent cation, TiO₂ doped with a trivalent cation, Fe₂O₃ dopedwith Ti⁺⁴, TiO, Ti₂O₃, non-stoichiometric zirconia oxide, anatase,beta″-alumina, alpha-alumina, Na-beta-alumina, Li-beta-alumina,(Na,Li)-beta-alumina, carbon, graphite, ZnO, CuS, FeS, CoO, calciumaluminate, char, Ni, Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃,FeTiO₃, LiNbO₃, MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x),FeTiO_(3-x), and combinations thereof.

The coating can be an amorphous material that is at a temperature belowthe material's glass transition temperature during the chemicalprocessing.

The frequency of said applied electromagnetic energy can be selectedfrom the group consisting of visible, ultraviolet, radio frequency,microwave, infrared, a variable frequency source, 915 MHz, 2.59 GHz, andcombinations thereof.

The structure of said susceptor can be selected from the groupconsisting of chiral-shaped, spire-like shaped, helical shaped, rod-likeshaped, plate-like shaped, acicular shaped, spherical shaped,ellipsoidal shaped, disc-shaped, irregular-shaped, plate-like shaped, ashape of a spiral antenna species for at least one wavelength of appliedelectromagnetic energy, a shape of an antenna specified for at least onwavelength of applied electromagnetic energy, needle-like shaped, twistshaped, rotini shaped, a woven structure and honeycomb-like structure,multi-cell structure, cylindrical shaped, tubular shaped, a reticulatedstructure, a foamed structure, a capillary structure, and combinationsthereof.

The coated susceptor preferably is permeable to a chemical species flow.

The coated susceptor can be used as a plurality of susceptors forchemical processing in the form of an operation selected from the groupconsisting of fluidized bed, a slurry, a fluid mixture of susceptors andchemicals species flow, a gaseous mixture of particulate susceptors anda chemical species flow, a packed bed, a solid mixture of particulatesusceptors and a solid chemical species flow, and combination thereof.

The coating preferably becomes reflective at the operating temperatureof the chemical processing.

The coated susceptor can further comprising a field concentrator whereinthe location of the field concentrator is selected group from the groupconsisting of on the coating, embedded in the coating, in the coating,and combinations thereof.

The coating can have a function is selected from the group consisting ofdriving chemical reactions, assisting in chemical reactions,polymerization, producing biodiesel through catalysis, synthesizingpharmaceuticals, reducing nitrogen oxides to nitrogen (N₂), reducing NOto nitrogen (N₂), reducing NO₂ to NO, reducing NO₂ to nitrogen (N₂),reducing SO_(x) to sulfur (S), reducing SO₃ to SO₂, reducing SO₄ to SO₂,reducing SO₃ to SO₂, chemical synthesis, sterilization, crackinghydrocarbons, decreasing the activation energy of a chemical process,oxidizing volatile organic compounds, oxidizing carbon monoxide tocarbon dioxide, reducing NOx in the presence of hydrocarbons,synthesizing biodiesel, reforming a hydrocarbon with a hydrogen donorspecies in the presence of H₂₃, reforming a hydrocarbon with methane inthe presence of H₂₃, reforming a hydrocarbon in the presence of methane,water and carbon dioxide, reforming a hydrocarbon in the presence ofmethane, water, hydrogen and carbon dioxide, reforming a hydrocarbon inthe presence of hydrogen and methane, polymerizing a hydrocarbon in thepresence of metal halides, reducing nitrogen oxides in the presence ofammonia, reducing nitrogen oxides in the presence of ammonium-containingcompounds, treating pollutants to form clean air which can be dischargedinto the environment in accordance to the law of the land, oxidativebond cleavage of a hydrocarbon, non-oxidative bond cleavage of ahydrocarbon, catalysis, field concentration or combination thereof,wherein the reaction occurs in physical phases of matter from the groupconsisting of a plasma, gas, solid, liquid, a fluid containingparticulates, and combinations thereof.

The operating temperature of said susceptor can be selected from thegroup of operating conditions consisting of a temperature which is abovethe Curie temperature of all the susceptor's materials, a temperaturewhich is below the Curie temperature of all the susceptor's materials, atemperature which is above Curie temperature of the non-matrix materialonly, a temperature which is above the Curie temperature of the matrixmaterial only, a temperature which is above the Curie temperature of allthe susceptor's materials causing increased absorption, a temperaturewhich is above the Curie temperature of the non-matrix causing increasedabsorption, a temperature which is above the Curie temperature of thematrix causing increased absorption, a temperature above the thermalrunaway temperature (critical temperature) of at least one of theconstituent phases, a temperature which is below the thermal runawaytemperature (critical temperature) of all the constituent phases, atemperature which is below the activation temperature of the intrinsicdielectric conduction species of all the phases present, a temperaturewhich is above the activation temperature of at least one intrinsicdielectric conducting species of all constituent phases, a temperatureabove the Curie temperature of the coating's material, a temperaturewhich is below the activation temperature of all extrinsic dielectricconducting species, a temperature which is above the activationtemperature of at least one extrinsic dielectric conducting species ofall the constituent phases, and combinations thereof.

The coating can be selected from the group consisting of controlling theamount of absorption of the applied electromagnetic energy by saidsusceptor material, regulating the temperature of the susceptor,controlling the amount of reflectivity of the applied electromagneticenergy by said susceptor, and combinations thereof.

The applied electromagnetic energy often applied in the form ofcontinuous energy, pulsed energy or a combination thereof.

The coating can contain a material with catalytic properties. Thematerial with catalytic properties can have a molecular structureselected from the group consisting of amorphous, rock salt, zinc blend,antifluorite, rutile, perovskite, spinel, inverse spinel, nickelarsenide, corundum, ilimenite, olivine, cesium chloride, fluorite,silica types, wurtzite, derivative structure of a known crystallinestructure, a superstructure of a known crystalline structure,orthosilicate, metasilicate, gibbsite, graphite, zeolite, carbide,nitride, montmorillonite, pyrophyllite, intermetallic semiconductor,metallic semiconductor, garnet, psuedoperovskite, orthoferrite,hexagonal ferrite, rare earth garnet, and a ferrite.

The material with catalytic properties also can have electronicproperties selected from the group consisting of a p-type material, ann-type material, a cation-doped p-type dominate material, an anion-dopedp-type dominate materials, a cation-doped n-type dominate material, ananion-doped n-type material, and combinations thereof.

The coated susceptor also can have a barrier coating placed between saidcoating material with catalytic properties and said susceptor to preventdeleterious chemical reaction between said coating material withcatalytic properties and the susceptor, to help prevent the poisoning ofthe catalyst, or to help prevent a combination thereof.

The form of the catalytic material can be selected from the groupconsisting of a catalyst that is a full coating on all susceptorsurfaces, a catalyst that is partial coating on all susceptor surfaces,a catalyst that is particulate catalyst on the susceptor's surface, acatalyst that is particulate catalyst contained in a coating that is onthe susceptor, a catalyst that is particulate catalyst on a coating thatis on the susceptor, a catalyst that is full coating of all susceptorsurfaces that has an additional coating between the catalyst and thesusceptor, a catalyst that is a partial coating of all susceptorsurfaces that has an additional coating between the catalyst and thesusceptor, and combinations thereof.

The material with catalytic properties can be a composite selected fromthe group of catalytic composites consisting of two or more catalyststhat perform the same function, two or more catalysts where at least onecatalyst performs a different function than the other catalyst, two ormore catalysts where at least one catalyst is a metallic species, two ormore catalyst where at least one catalyst has a Curie temperature, andcombinations thereof.

The material with catalytic properties can have a function selected fromthe group consisting of driving chemical reactions, assisting inchemical reactions, polymerization, producing biodiesel throughcatalysis, synthesizing pharmaceuticals, reducing nitrogen oxides tonitrogen (N₂), reducing NO to nitrogen (N₂), reducing NO₂ to NO,reducing NO₂ to nitrogen (N₂), reducing SO_(x) to sulfur (S), reducingSO₃ to SO₂, reducing SO₄ to SO₂, reducing SO₃ to SO₂, chemicalsynthesis, sterilization, cracking hydrocarbons, decreasing theactivation energy of a chemical process, oxidizing volatile organiccompounds, oxidizing carbon monoxide to carbon dioxide, reducing NOx inthe presence of hydrocarbons, synthesizing biodiesel, reforming ahydrocarbon with a hydrogen donor species in the presence of H₂₃,reforming a hydrocarbon with methane in the presence of H₂₃, reforming ahydrocarbon in the presence of methane, water and carbon dioxide,reforming a hydrocarbon in the presence of methane, water, hydrogen andcarbon dioxide, reforming a hydrocarbon in the presence of hydrogen andmethane, polymerizing a hydrocarbon in the presence of metal halides,reducing nitrogen oxides in the presence of ammonia, reducing nitrogenoxides in the presence of ammonium-containing compounds, treatingpollutants to form clean air which can be discharged into theenvironment in accordance to the law of the land, oxidative bondcleavage of a hydrocarbon, non-oxidative bond cleavage of a hydrocarbon,catalysis, field concentration or combination thereof, wherein thereaction occurs in physical phases of matter from the group consistingof a plasma, gas, solid, liquid, a fluid containing particulates, andcombinations thereof.

The material with catalytic properties also can be selected from thegroup of materials consisting of a photocatalytic material activated byelectromagnetic energy in the ultraviolet region, a photo catalyticmaterial activated by electromagnetic energy in the visible region, ainfrared catalytic materials activated by electromagnetic energy in theinfrared region, a catalytic materials activated by electromagneticenergy in the microwave region, a catalytic material activated byelectromagnetic energy in the radio frequency region, and combinationsthereof.

The material with catalytic properties also can be selected from thegroup of consisting of materials that are a precious metal, Fe, Co, Ni,Pt, Pd, Au, Ag, chalcogenide, metal alloy, boride, Fe-based alloy, aprecious metal alloy, an artificial dielectric, an artificial dielectricmaterial where the volume fraction of the non-matrix species is lessthat 50 volume percent, an artificial dielectric material where thevolume fraction of the non-matrix species is equal to or greater than 50volume percent, Co-alloy, Ni-alloy, antiferromagnetic,antiferroelectric, paramagnetic, a material with a Curie temperature,glassy, metallic, a material that produces thermionic emissions, amaterial that is thermoelectric, a cermet, a ceramic glaze with metalparticles, ferrimagnetic, ferroelectric, ferromagnetic, semiconducting,conducting, solid-state ionic conductor, non-stoichiometric carbide,non-stoichiometric oxide, oxycarbide, oxynitride, carbonitride, oxide,nitride, intermetallic, hydroxide, thermoluminescent, fluorescent,boride, a material with low dielectric constant and low dielectriclosses, a material with a high dielectric constant and low dielectriclosses, silicide, nitride, aluminide, a material with a high dielectricconstant and high dielectric losses, a material with a high dielectricconstant and moderate dielectric losses, carbide, oxide, anatase,sulfide, sulfate, carbonate, FeO, CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃,Fe₃O₄, CuO—MnO₂, Li₂O—NiO, TiO₂ doped with a divalent cation, TiO₂ dopedwith a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, Cu₂O—MnO₂, Li₂O—Cu₂O,Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, TiO, Ti₂O₃, non-stoichiometriczirconia oxide, anatase, beta″-alumina, alpha-alumina, Na-beta-alumina,Li-beta-alumina, (Na,Li)-beta-alumina, carbon, graphite, ZnO, CuS, FeS,CoO, calcium aluminate, char, Ni, Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃,NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃, MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x),CoTiO_(3-x), FeTiO_(3-x), ZnO_(1-x), SmLiO₂, LaLiO₂, LaNaO₂, SmNaO₂,(SmLiO₂)_(0.8)(CaOMgO)_(0.2), (LaLi₂)_(0.7)(SrOMgO)_(0.3),(NdLiO₂)_(0.8)(CaMgO)_(0.2), strontium-doped lanthium oxide supported onmagnesium oxide, a material derived by processing a clay mineral withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tononreversible crystalline and/or glass phases, a material derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to nonreversible crystalline and/or glass, a materialderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, a material derived by processingBrucite with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe Brucite material to non-reversible crystalline material, a materialderived by processing a Gibbsite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline material, and combinations thereof.

The clay mineral is selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite, and combinations thereof.

The coating on the susceptor can be used as a reactant with a chemicalspecies flow for desired products or with a pollutant species to treatpollutants for producing clean air which can be discharge into theenvironment in accordance with the law of the land.

The coating can be a carbon-containing species that reacts with achemical species flow to produce hydrogen, higher order chemicalspecies, lower order chemical species, carbon monoxide, carbon dioxideor combinations thereof.

The coating can contain a reactant selected from the group consisting ofNa-beta alumina, Li-beta alumina, NaOH, LiOH, CaCO₃, Ca(OH)₂,gamma-alumina, alpha-alumina, lithium complexes, a lithium complexpartially adsorbed on partially calcine bauxite, a sodium complexpartially adsorbed on partially calcine bauxite, silica, a cation-dopedsilica or combination thereof, to chemically react with a chemicalspecies flow containing a fluorine species, a chlorine species, a sulfurspecies, and combinations thereof.

The coating also can contain a reactant selected from the groupconsisting of urea, ammonia, cyanuric acid, ammonium carbamate, ammoniumbicarbonate, mixtures of ammonia and ammonium bicarbonate, ammoniumformate, ammoniumoxialate, sources of a nydroxyl radicals, sources ofhydrogen radicals, milk, sugar, molasses, polysaccharides, a reducingagent, and combinations thereof, to chemically react with a chemicalspecies flow containing a nitrogen oxide or nitrogen oxides to produceNitrogen (N₂).

Particle-Size Effects, Materials for the Matrix, Applications, MaterialsMixture, Physical Properties, Atmospheres, Operating Temperature andOther Properties

The invention also is an electromagnetic susceptor for chemicalprocessing comprising a matrix material that surrounds a non-matrixmaterial that is made from a material that is different from the matrixmaterial, wherein:

-   -   a. the matrix material is constructed of material having lower        dielectric losses compared to the non-matrix material;    -   b. the non-matrix material initially absorbs electromagnetic        energy applied to the electromagnetic susceptor to a greater        extent than the matrix material;    -   c. the non-matrix material produces subsequent heat in the        matrix material; and    -   d. the greatest length of measurement of the electromagnetic        susceptor is between one nanometer and 10 meters.

The non-matrix material also can produce reflection.

The susceptor can be used in an atmosphere selected from the groupconsisting of a reducing atmosphere, an oxidizing atmosphere, anatmosphere at one atmosphere of pressure, an atmosphere at less than oneatmosphere of pressure, an atmosphere at greater than one atmosphere ofpressure, and combinations thereof.

The susceptor's function can be selected from the group consisting ofdriving chemical reactions, assisting in chemical reactions,polymerization, producing biodiesel through catalysis, synthesizingpharmaceuticals, reducing nitrogen oxides to nitrogen (N₂), reducing NOto nitrogen (N₂), reducing NO₂ to NO, reducing NO₂ to nitrogen (N₂),reducing SO_(x) to sulfur (S), reducing SO₃ to SO₂, reducing SO₄ to SO₂,reducing SO₃ to SO₂, chemical synthesis, sterilization, crackinghydrocarbons, decreasing the activation energy of a chemical process,oxidizing volatile organic compounds, oxidizing carbon monoxide tocarbon dioxide, reducing NOx in the presence of hydrocarbons,synthesizing biodiesel, reforming a hydrocarbon with a hydrogen donorspecies in the presence of H₂O, reforming a hydrocarbon with methane inthe presence of H₂O, reforming a hydrocarbon in the presence of methane,water and carbon dioxide, reforming a hydrocarbon in the presence ofmethane, water, hydrogen and carbon dioxide, reforming a hydrocarbon inthe presence of hydrogen and methane, polymerizing a hydrocarbon in thepresence of metal halides, reducing nitrogen oxides in the presence ofammonia, reducing nitrogen oxides in the presence of ammonium-containingcompounds, treating pollutants to form clean air which can be dischargedinto the environment in accordance to the law of the land, oxidativebond cleavage of a hydrocarbon, non-oxidative bond cleavage of ahydrocarbon, catalysis, field concentration or combination thereof,wherein the reaction occurs in physical phases of matter from the groupconsisting of a plasma, gas, solid, liquid, a fluid containingparticulates, and combinations thereof.

The operating temperature of the susceptor can be selected from thegroup consisting of operating conditions consisting of a temperaturewhich is above the Curie temperature of all the susceptor's materials, atemperature which is below the Curie temperature of all the susceptor'smaterials, a temperature which is above Curie temperature of thenon-matrix material only, a temperature which is above the Curietemperature of the matrix material only, a temperature which is abovethe Curie temperature of all the susceptor's materials causing increasedabsorption, a temperature which is above the Curie temperature of thenon-matrix material causing increased absorption, a temperature which isabove the Curie temperature of the matrix material causing increasedabsorption, a temperature above the thermal runaway temperature(critical temperature) of at least one of the constituent phases, atemperature which is below the thermal runaway temperature (criticaltemperature) of all the susceptor's constituent phases, a temperaturewhich is below the activation temperature of the intrinsic dielectricconduction species of all the phases present, a temperature which isabove the activation temperature of at least one intrinsic dielectricconducting species of all constituent phases, a temperature which isbelow the activation temperature of all extrinsic dielectric conductingspecies, a temperature which is above the activation temperature of atleast one extrinsic dielectric conducting species of all the constituentphases, and combinations thereof.

The particle size of the non-matrix material through interaction withthe applied electromagnetic energy can provide a utility to effect aphysical property of said susceptor selected from the group consistingof mechanical properties, thermal properties, optical properties of thenon-matrix material, optical properties of the susceptor, absorption ofelectromagnetic energy, reflection of electromagnetic energy,transmission of electromagnetic energy, scattering of electromagneticenergy, electromagnetic properties, corrosive properties, wearproperties, piezoelectric properties, dielectric properties, magneticproperties, electric properties, susceptibility to the appliedelectromagnetic energy, susceptibility to the fluorescentelectromagnetic energy, conductivity, controlling the chemicalcompatibility between the non-matrix material and the matrix material,regulating the temperature of said susceptor, regulating the temperatureof a process, regulating the amount of electromagnetic energy availablefor chemical process, regulating the amount of electromagnetic energyavailable for a physical process, and combinations thereof.

The particle size of the matrix material through interaction with theapplied electromagnetic energy can provide a utility to effect aphysical property of said susceptor selected from the group consistingof mechanical properties, thermal properties, optical properties of thematrix material, optical properties of the susceptor, absorption ofelectromagnetic energy, reflection of electromagnetic energy,transmission of electromagnetic energy, scattering of electromagneticenergy, electromagnetic properties, corrosive properties, wearproperties, piezoelectric properties, dielectric properties, magneticproperties, electric properties, susceptibility to the appliedelectromagnetic energy, susceptibility to the fluorescentelectromagnetic energy, conductivity, controlling the chemicalcompatibility between the non-matrix material and the matrix material,regulating the temperature of said susceptor, regulating the temperatureof a process, regulating the amount of electromagnetic energy availablefor chemical process, regulating the amount of electromagnetic energyavailable for a physical process, and combinations thereof.

The non-matrix material preferably has a particle size of less than theUS Standard Mesh size 325. The particle size of the non-matrix materialcan be selected from the group consisting of mono-modal, multi-modal,heterogeneous and homogeneous particle sizes, and combinations thereof.The particle-size of the matrix material can be selected from the groupconsisting of mono-modal distribution, multi-modal distribution,heterogeneous and homogeneous particle sizes, and combinations thereof.

The matrix material can be selected from the group consisting ofmaterials that are metallic, amorphous, polycrystalline,antiferromagnetic, antiferroelectric, paramagnetic, an artificialdielectric material where the volume fraction of the non-matrix speciesis less that 50 volume percent, an artificial dielectric material wherethe volume fraction of the non-matrix species is equal to or greaterthan 50 volume percent, a material that produces thermionic emissions, amaterial that is thermoelectric, a cermet, a material with a Curietemperature, glassy, metallic, ferrimagnetic, ferroelectric,ferromagnetic, semiconducting, conducting, a solid-state ionicconductor, a non-stoichiometric carbide, a non-stoichiometric oxide, anoxycarbide, an oxynitride, a carbonitride, an intermetallic, ahydroxide, a non-stoichiometric nitride, thermoluminescent, anon-stoichiometric Ilmenitic structure, fluorescent, a boride, amaterial with low dielectric constant and low dielectric losses, amaterial with a high dielectric constant and low dielectric losses, asilicide, a nitride, an aluminide, a material with a high dielectricconstant and high dielectric losses, a material with a high dielectricconstant and moderate dielectric losses, a carbide, an oxide, anatase, asulfide, a sulfate, a carbonate, a glass ceramic, photochromatic,thermochromatic, a phase separated glass, an ionic conductor, andcombinations thereof.

The matrix material also can be selected from group consisting of FeO,CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂, Cu₂O—MnO₂, Li₂O—Cu₂O,Li₂O—CuO, Li₂O-MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, Li₂O—NiO, TiO₂ doped with a divalentcation, TiO₂ doped with a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, TiO,Ti₂O₃, non-stoichiometric zirconia oxide, anatase, beta″-alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na,Li)-beta-alumina,carbon, graphite, ZnO, CuS, FeS, CoO, calcium aluminate, char, Ni, Co,Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), andcombinations thereof.

The matrix material can be a composite material.

Defects can be introduced into a crystalline molecular structure of theconstituent materials to effect the susceptor's physical propertiesselected from the group consisting of mechanical properties, thermalproperties, chemical properties, optical properties, magneticproperties, electric properties, property of susceptibility toelectromagnetic energy, conductivity, catalytic properties,electromagnetic properties, and combinations thereof. The defect can beselected from the group consisting of an intrinsic defect, an extrinsicdefect, a defect from cation substitution, a defect from anionsubstitution, and combinations thereof.

The non-matrix material and matrix material can have the same Bravaislattice structure, similar crystalline structure and chemicalcomposition where the non-matrix material contains ionic substitutionwhich produces greater dielectric losses compared to the matrixmaterial. The non-matrix material and matrix material also can have thesame Bravais lattice structure, similar crystalline structure andsimilar chemical composition where at least one phase of the matrixmaterial contains ionic substitution which produces greater dielectriclosses compared to remaining matrix material.

The electromagnetic susceptor can further comprises a barrier coatingbetween the non-matrix material and matrix material to preventdeleterious chemical reaction.

The electromagnetic susceptor also can have a constituent material usedto decrease the power required to obtain the desired operatingtemperature for the desired use and the form of the constituent materialis selected from the group consisting of a coating, non-matrix material,a matrix material, a field concentrator, and combinations thereof.

The susceptor can be used for the adsorption of a chemical species,absorption of a chemical species, or combinations thereof.

The thermal conductivity of the susceptor can be used to control theheat transfer between the dielectric susceptor and chemical species flowand the method of controlling the thermal conductivity of the dielectricsusceptor is selected from the group consisting of controlling the porestructure, controlling the volume of the porosity, using a compositestructure that contains a material with a high thermal conductivity,using a coating on the susceptor that increases the thermal conductivityof the susceptor's surface, grading the pore structure by flamepolishing the outer surface of the dielectric susceptor, andcombinations thereof.

The non-matrix material preferably has a thermal expansion mismatchbetween the non-matrix material and matrix of less than 20%.

The applied electromagnetic energy can initially intercepts thesusceptor in a manner selected from the group consisting of one side ofthe susceptor, more than one side of the susceptor, all sides of thesusceptor, at opposing sides of the susceptor and at adjacent sides ofthe susceptor, and at least one wavelength of applied electromagneticinitially entering the susceptor at set of opposing sides of thesusceptor's surface that have the largest surface area of the susceptorwith also at least one different wavelength of applied electromagneticenergy initially entering the susceptor at a different set of twoopposing sides.

The dimensions of the susceptor can be designed to allow the susceptorto be placed into a cavity that allows for the cavity's dimensions toaccommodate the optical dielectric properties of the appliedelectromagnetic energy or energies so to form a resonate cavity thataccommodates a multiple of ¼ the wavelength of the appliedelectromagnetic energy in the susceptor with respect to the opticalproperties of the susceptor where the multiple is equal to or greaterthan one. At least one dimension of the susceptor can accommodate thelargest wavelength when more then one wavelength is applied to thesusceptor. The dimensions of the susceptor can be made to accommodate aspecific transverse electromagnetic mode.

The susceptor can be placed in a cavity that has a shape that isselected from the group consisting of irregular shaped, orthorhombic,cylindrical, spherical, cubic, hemispherical, ellipsoidal, tubular,equilateral polyhedral, square, rectangular, and polyhedral. The cavityalso can be tuned.

The interaction between the dielectric properties of at least onenon-matrix material and at least one wavelength of the appliedelectromagnetic energy can be selected from the group of consisting ofat least 5% transparency to at least one wavelength of appliedelectromagnetic energy, at least 5% absorption of at least onewavelength of applied electromagnetic energy, at least 5% scattering ofat least one wavelength of applied electromagnetic energy, at least 5%reflection of at least one wavelength of applied electromagnetic energy,and combination thereof.

The interaction between the dielectric properties of the matrix materialand at least one wavelength of the applied electromagnetic energy alsocan be selected from the group of consisting of at least 5% transparencyto at least one wavelength of applied electromagnetic energy, at least5% absorption of at least one wavelength of applied electromagneticenergy, at least 5% reflection of at least one wavelength of appliedelectromagnetic energy, at least 5% scattering of at least onewavelength of applied electromagnetic energy, and combinations thereof.

During the chemical process the temperature of at least part of thematrix material can be greater than the temperature of the non-matrixmaterial. During the chemical process the temperature of at least partof the non-matrix material also can be greater than the temperature ofthe matrix material.

The matrix material can become reflective at a temperature greater than0° C.

The susceptor can be used as a reactant with a chemical species flow fordesired products or with a pollutant species to treat pollutants forproducing clean air which can be discharge into the environment inaccordance with the law of the land.

The susceptor can be a carbon-containing species that reacts with achemical species flow to produce hydrogen, higher order chemicalspecies, lower order chemical species, carbon monoxide, carbon dioxideor combinations thereof.

The susceptor can be a reactant selected from the group consisting ofNa-beta alumina, Li-beta alumina, NaOH, LiOH, CaCO₃, Ca(OH)₂,gamma-alumina, alpha-alumina, lithium complexes, a lithium complexpartially adsorbed on partially calcine bauxite, a sodium complexpartially adsorbed on partially calcine bauxite, silica, a cation-dopedsilica or combination thereof, that chemically reacts with a chemicalspecies flow containing a fluorine species, a chlorine species, a sulfurspecies, and combinations thereof.

The susceptor also can a reactant selected from the group consisting ofurea, ammonia, cyanuric acid, ammonium carbamate, ammonium bicarbonate,mixtures of ammonia and ammonium bicarbonate, ammonium formate,ammoniumoxialate, sources of a nydroxyl radicals, sources of hydrogenradicals, milk, sugar, molasses, polysaccharides, a reducing agent, andcombinations thereof, that chemically reacts with a chemical speciesflow containing a nitrogen oxide or nitrogen oxides to produce Nitrogen(N₂).

Clay Systems

The description of a material that is derived by a clay is important.There are at least four (4) ways that a clay can be described:

-   -   (1) An extrinsically bonded clay structure: The clay material        using water or another binding agent for bonding the clay to        create a structure. For example, a piece of pottery formed by        throwing clay on a potter's wheel;    -   (2) Non extrinsic bonded clay structure and clay powder: A piece        of pottery held together by van der Waals forces after a drying        process has removed the bonding water, or dry clay powder;    -   (3) Crystalline species derived from a clay: Clay, whether as a        formed structure or powder, can be heated above 1000° C. to        synthesize an intimate mixture of mullite (an aluminosilicate        phase) and a silica phase; and    -   (4) An intermediate structure derived from a clay: The clay        structure contains what is known in the trade as water of        crystallization. An intermediate structure that is known as a        pseudomorphic structure occurs when clay is heated above 500° C.        Between about 500° C. to about 980° C. or greater, the        pseudomorphic structure is the matrix of the original        crystalline structure of the clay containing large anion        vacancies from removal of (OH⁻) ions from original crystalline        structure. This pseudomorphic structure is probably metastable        up to 1100° C. This temperature range is dependent upon        atmospheric conditions and particle size.

The invention also is an electromagnetic susceptor for chemicalprocessing having a matrix material that surrounds a non-matrix materialthat is made from a material that is different from the matrix material,wherein:

-   -   a. the matrix material is constructed of a sintered ceramic        material having lower dielectric losses compared to the        non-matrix material;    -   b. the non-matrix material initially absorbs electromagnetic        energy applied to the electromagnetic susceptor to a greater        extent than the matrix material; and    -   c. the non-matrix material produces subsequent heat in the        matrix material.

The non-matrix material also can produce reflection.

The matrix material can be a sintered ceramic having a composition thatcan have crystalline and glassy phases that is based uponmagnesia-silica chemistry where the summation of the matrix material'sweight fraction of magnesium (Mg), silica (Si) and oxygen (O) is atleast 85% by weight, and comprises:

-   -   a. between 5% by weight and 99% by weight of the total weight of        MgO in the matrix material, and up to 100% by weight of the MgO        exists as a crystalline phase in a crystalline system selected        from the group consisting of magnesium silicate, periclase, and        combinations thereof;    -   b. between 5% by weight and 99% by weight of the total weight of        SiO₂ in the matrix material and up to 100% by weight of the SiO₂        exists as a crystalline phase in a crystalline system selected        from the group consisting of magnesium silicate, silica, and        combinations thereof; and    -   c. the balance of the matrix material's total weight being        selected from cations other that Si and Mg substituted in a        crystalline phase selected from the group consisting of        magnesium silicate, silica, periclase, and combinations thereof,        at least one cation species other than or in addition to Mg and        Si in a glass phase, a crystalline phase other than magnesium        silicate, silica and periclase that has at least one other        cation species other than or in addition to Mg and Si, and        combinations thereof.

The matrix material also can be a sintered ceramic having a compositionwhich can have crystalline and glassy phases based upon alumina-silicachemistry where the summation of the matrix material's weight fractionof aluminum (Al), silica (Si) and oxygen (O) is at least 80% by weight,and comprises:

-   -   a. between 5% by weight and 99% by weight of the total weight of        Al₂O₃ in the matrix material, and up to 100% by weight of the        Al₂O₃ exists as a crystalline phase in a crystalline system        selected from the group consisting of aluminosilicate, alumina,        and combinations thereof;    -   b. between 5% by weight and 99% by weight of the total weight of        SiO₂ in the matrix material, and up to 100% by weight of the        SiO₂ exists as a crystalline phase in a crystalline system        selected from the group consisting of aluminosilicate, silica,        or combinations thereof; and    -   c. the balance of the matrix material's total weight being        selected from cations other than Al and Si substituted in a        crystalline phase selected from the group consisting of an        aluminosilicate, an alumina, a silica, and combinations thereof,        at least one cation species other than or in addition to Si and        Al in a glass phase, a crystalline phase other than        aluminosilicate, silica and alumina that has at least one other        cation species other than or in addition to Mg and Si, and        combinations thereof.

The matrix material can be selected from the group consisting ofstabilized zirconia, partially stabilized zirconia, and combinationsthereof.

The electromagnetic susceptor can comprise a matrix material that isnonreflective of electromagnetic energy and that surrounds a non-matrixmaterial that is reflective of electromagnetic energy and that is madefrom a material that is different from the matrix material and furthercomprising a field concentrator and a coating between saidelectromagnetic susceptor and said field concentrator that preventsdeleterious chemical reaction between said electromagnetic susceptor andsaid field concentrator.

The field concentrator can be made from a material that is selected fromthe group consisting of a conductor, semi-conductor, materials with aCurie temperature, and an ionic conducting ceramic. The fieldconcentrator can be of a size that is designed to lessen any deleteriouschemical reaction between materials of construction of theelectromagnetic susceptor and the material of the field concentrator.The field concentrator also can be made from a material that is selectedfrom the group consisting of MnO₂—CuO, Li₂O—NiO, Li₂O—MnO₂, Li₂O—CuO,TiO₂ doped with a divalent cation, and TiO₂ doped with a trivalentcation, Fe₂O₃ with Ti⁺⁴.

The matrix material can be selected from the group of crystalline phasesconsisting of enstatite, clino-enstatite, forsterite, cordierite,periclase, alpha-quartz, beta-quartz, alpha-trydimite, beta′-trydimite,beta″-trydimite, alpha-crystobalite, beta-crystobalite, anorthosilicate, a pyrosilicate, a metasilicate, wollastonite, albite,orthoclase, microcline, sillimanite, alpha-alumina, beta-alumina,gamma-alumina, mullite, olivine, anorthite, and combinations thereof.

At least a part of the matrix material can be a glassy phase selectedgroup consisting of amorphous silica, aluminosilicate glass,aluminosilicate glass with glass modifiers, phosphate-based glass, phaseseparated glass, germanium-based glass, soda-lime-silicate glass,borosilicate glass, sodium silicate glass, calcium silicate glass,soda-lime-aluminosilicate glass, chalcogenide, and combinations thereof.

The matrix material also can be a sintered ceramic having a compositionwhich has crystalline and glassy phases based uponmagnesia-alumina-silica chemistry where the summation of the matrixmaterial's weight fraction of aluminum (Al), magnesium (Mg), silica (Si)and oxygen (O) is at least 80% by weight, comprising:

-   -   a. between 5% by weight and 99% by weight of the total weight of        Al₂O₃ in the matrix material, and up to 100% by weight of the        Al₂O₃ exist as a crystalline phase in a crystalline system from        the group consisting of magnesium aluminosilicate, alumina,        aluminosilicate, magnesium aluminate, and combinations thereof;    -   b. between 5% by weight and 99% by weight of the total weight of        MgO in the matrix material, and up to 100% by weight of the MgO        exists as a crystalline phase in a crystalline system selected        from the group consisting of magnesium aluminosilicate,        magnesium silicate, periclase, magnesium aluminate, and        combinations thereof;    -   c. between 5% by weight and 99% by weight of the total weight        SiO₂ in the matrix material, and up to 100% by weight of the        SiO₂ exists as a crystalline phase in a crystalline system        selected from the group consisting of silica, magnesium        aluminosilicate, magnesium silicate, and combinations thereof;        and    -   d. the balance of the matrix material's total weight being        selected from other than Mg, Al and Si substituted in a        crystalline phase in a crystalline system selected from the        group consisting of aluminosilicate, magnesium aluminosilicate,        magnesium silicate, magnesium aluminate, alumina, silica,        periclase, and combinations thereof, at least one other cation        species other than or in addition to Mg, Al and Si in a glass        phase, a crystalline phase other than magnesium aluminosilicate,        aluminosilicate, magnesium silicate, magnesium aluminate,        silica, periclase and alumina that has at least one other cation        species other than or in addition to Mg, Al, and Si, and        combinations thereof.

The matrix material can be selected from the group consisting ofalumina, aluminosilicate ceramic, magnesium aluminosilicate ceramic,magnesium silicate, calcium silicate, crystalline form of silica,calcium aluminosilicate, clay, zeolite, magnesium oxide, sialon,oxynitride, inorganic glass, organic glass, organic polymer, crystallineorganic polymer, solid solution, ceramic matrix composite, metal matrixcomposite, polymer composite, cordierite, quartz, enstatite, forsterite,steatite, nitride, porcelain, high-temperature porcelain, glass ceramic,phase separated glass, lithium-aluminosilicate, Teflon, organiccopolymer, polycarbonate, polypropylene, polystyrene, polyethylene,polyester, polytetrafluoroethylene, materials derived by processing aclay mineral with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe clay material to nonreversible crystalline and/or glass phases,materials derived by processing talc with heat to a temperature and fortime period above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the talc material to nonreversiblecrystalline and/or glass, a material derived by processing a zeolitewith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the zeolitematerial to non-reversible crystalline and/or glass phases, materialsderived by processing Brucite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the Brucite material to non-reversiblecrystalline material, materials derived by processing a Gibbsite withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline material, and combinations thereof.

The matrix material can be selected from the group consisting ofthermoluminescent materials, fluorescent materials, low-lossdielectrics, and combinations thereof. The fluorescent materialsfluoresce upon exposure of a dye to the applied electromagnetic energyand the dye is embedded in a matrix that is primarily transparent to theradiation emitted from the dye. The fluorescent materials producefluorescent radiation selected from the group of electromagneticfrequencies consisting of ultraviolet radiation, visible radiation,infrared radiation, and combinations thereof.

The non-matrix material can be selected from the group consisting ofmaterials that are amorphous, metallic, ferrimagnetic, ferroelectric,ferromagnetic, semiconducting, conducting, solid-state ionic conductor,non-stoichiometric carbides, non-stoichiometric oxides, oxycarbides,oxynitrides, carbonitrides, intermetallic, thermoluminescent,fluorescent, borides, suicides, nitrides, aluminides, carbides, oxides,sulfides, composite materials, organic polymeric matrix composites,ceramic matrix composites, metal matrix composites, organic copolymers,amorphous organic polymers, crystalline organic polymers,polycarbonates, polypropylene, polystyrene, polyethylene, polyester,polytetrafluoroethylene, solid solutions, sulfates, non-stoichiometricillmenitic structures, mica, non-stoichiometric zinc oxide,non-stoichiometric nitrides, crystalline forms of silica,antiferromagnetics, antiferroelectrics, materials with low dielectricconstant and low dielectric losses, materials with high dielectricconstant and low dielectric losses, paramagnetics, materials with highdielectric constant and high dielectric losses, materials with a highdielectric constant and moderate dielectric losses, hydroxides,thermochromatics, photochromatics, metal alloys, artificial dielectricmaterials where the volume fraction of the non-matrix species is lessthat 50 volume percent, artificial dielectric materials where the volumefraction of the non-matrix species is equal to or greater than 50 volumepercent, materials that produce thermionic emissions, materials that arethermoelectric, cermet, materials with a Curie temperature, sulfates,anatase, carbonate, materials derived by processing a clay mineral withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline and/or glass phases, materials derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to non-reversible crystalline and/or glass, materialsderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, materials derived by processing Brucitewith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the Brucitematerial to nonreversible crystalline material, materials derived byprocessing a Gibbsite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the clay material to nonreversible crystallinematerial, and combinations thereof. The non-matrix material also can beselected from the group consisting of FeO, CuO Cu₂O, MnO₆₂, Mn₂O₅, NiO,Fe₂O₃, Fe₃O₄, CuO—MnO₂, Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO, Li₂O—MnO₂,Li₂O—NiO, ZnO and combinations thereof.

The non-matrix material further can be selected from the groupconsisting, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂, TiO₂ dopedwith a divalent cation, TiO₂ doped with a trivalent cation, Fe₂O₃ dopedwith Ti⁺⁴, a non-stoichiometric titanium oxide, TiO, Ti₂O₃, anon-stoichiometric zirconia oxide, anatase, beta″-alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na, Li)-beta-alumina,a carbon, a graphite, CuS, FeS, CoO, a calcium aluminate, a char, Ni,Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), quartz,a crystalline form of silica, and combinations thereof.

The applied electromagnetic energy can be a radiation selected from thegroup consisting of ultra-violet, infrared, microwave, visible, radiofrequency, 915 MHz, 2.45 GHz, a variable frequency source, andcombinations thereof.

The structure of the susceptor can be selected from the group consistingof chiral-shaped, spire-like shaped, helical shaped, rod-like shaped,plate-like shaped, acicular shaped, spherical shaped, ellipsoidalshaped, disc-shaped, irregular-shaped, plate-like shaped, a shape of aspiral antenna species for at least one wavelength of appliedelectromagnetic energy, a shape of an antenna specified for at least onwavelength of applied electromagnetic energy, needlelike shaped, twistshaped, rotini shaped, a woven structure and honeycomb-like structure,multi-cell structure, cylindrical shaped, tubular shaped, a reticulatedstructure, a foamed structure, a capillary structure, and combinationsthereof.

The shape of the non-matrix material can be selected from a groupconsisting of chiral, spire-like, helical, rod-like, plate-like,acicular, spherical, ellipsoidal, disc-shaped, irregular-shaped,plate-like, needle-like, and twist.

The interaction between the dielectric properties of the susceptor andat least one wavelength of the applied electromagnetic energy can beselected from the group of interactions with applied electromagneticenergy consisting of at least 5% transparent to at least one wavelengthof applied electromagnetic energy, at least 5% scattering to at leastone wavelength of applied electromagnetic energy, at least 5% absorptiveof at least one wavelength of applied electromagnetic energy, at least5% reflective of at least one wavelength of applied electromagneticenergy, and combinations thereof.

The non-matrix material can have a volume fraction greater than 50% andless than 98%. The non-matrix material can have a volume fractiongreater than 0.001% and less than or equal to 50%.

The susceptor can further comprise a coating, a catalyst, and/or a fieldconcentrator.

The susceptor can have a volume fraction of porosity and pore-sizedistribution which are used to control the physical properties of thesusceptor selected from the group consisting of dielectric properties,thermal properties, mechanical properties, optical properties, corrosiveproperties, magnetic properties, electric properties, conductiveproperties, absorptive properties, susceptibility of appliedelectromagnetic energy, wear properties, and combinations thereof.

The matrix material also can be a sintered ceramic having a compositionwhich has crystalline and glassy phases based uponmagnesia-alumina-silica chemistry where the summation of the matrixmaterial's weight fraction of aluminum (Al), magnesium (Mg), silica (Si)and oxygen (O) is at least 80% by weight, wherein:

-   -   a. the weight percent of Al₂O₃ in the matrix material is between        5% by weight and 99% by weight, and up to 100% by weight of the        Al₂O₃ exists as a crystalline phase in a crystalline system from        the group consisting of magnesium aluminosilicate, alumina,        aluminosilicate, magnesium aluminate, and combinations thereof;    -   b. the weight percent of MgO in the matrix material is between        5% by weight and 99% by weight, and up to 100% by weight of the        MgO exists as a crystalline phase in a crystalline system        selected from the group consisting of magnesium aluminosilicate,        magnesium silicate, periclase, magnesium aluminate, and        combinations thereof;    -   c. the weight percent SiO₂ in the matrix material is between 5%        by weight and 99% by weight, and up to 100% by weight of the        SiO₂ exists as a crystalline phase in a crystalline system        selected from the group consisting of silica, magnesium        aluminosilicate, magnesium silicate, and combinations thereof;        and    -   d. the balance of the matrix material's weight percent is cation        substitution other than Mg, Al and Si in a crystalline phase in        a crystalline system selected from the group consisting of        aluminosilicate, magnesium aluminosilicate, magnesium silicate,        magnesium aluminate, alumina, silica, periclase, and        combinations thereof, at least one other cation species other        than or in addition to Mg, Al and Si in a glass phase, a        crystalline phase other than magnesium aluminosilicate,        aluminosilicate, magnesium silicate, magnesium aluminate,        silica, periclase and alumina that has at least one other cation        species other than or in addition to Mg, Al, and Si, and        combinations thereof.

The matrix material also can be a sintered ceramic having a compositionwhich has crystalline and glassy phases based upon calcia-alumina-silicachemistry where the summation of the matrix material's weight fractionof aluminum (Al), calcium (Ca), silica (Si) and oxygen (O) is at least80% by weight, wherein:

-   -   a. The weight percent of Al₂O₃ in the matrix material is between        5% by weight and 99% by weight, and up to 100% by weight the        Al₂O₃ exist as a crystalline phase in a crystalline system from        the group consisting of calcium aluminosilicate, alumina,        calcium aluminate, aluminosilicate, and combinations thereof;    -   b. the weight percent of CaO in the matrix material is between        5% by weight and 99% by weight, and up to 100% by weight of the        CaO exists as a crystalline phase in a crystalline system        selected from the group consisting of calcium aluminosilicate,        calcium silicate, calcium aluminate, calcia, and combinations        thereof;    -   c. the weight percent SiO₂ in the matrix material is between 5%        by weight and 99% by weight, and up to 100% by weight of the        SiO₂ exists as a crystalline phase in a crystalline system        selected from the group consisting of silica, calcium        aluminosilicate, calcium silicate, and combinations thereof; and    -   d. the balance of the matrix material's weight is cation        substitution other than Ca, Al and Si in a crystalline phase in        a crystalline system selected from the group consisting of        aluminosilicate, calcium aluminosilicate, calcium aluminate,        calcium silicate, alumina, calcia, silica, and combinations        thereof, at least one other cation species other than or in        addition to Ca, Al and Si in a glass phase, a crystalline phase        other than a calcium aluminosilicate, calcium aluminate,        aluminosilicate, calcium silicate, silica, calcia and alumina        that has at least one other cation species other than or in        addition to Ca, Al, and Si, and combinations thereof.

Ozone Production

The invention also includes a method of producing ozone from interactionon an electromagnetic susceptor between field concentrators on theelectromagnetic susceptor and applied electromagnetic energy applied tothe susceptor, comprising the steps of:

-   -   a. controlling the distance between field concentrators on the        electromagnetic susceptor;    -   b. using a low loss, low dielectric constant material of        construction for the electromagnetic susceptor; and    -   c. applying electromagnetic energy to the electromagnetic        susceptor to produce ozone.

A second embodiment of the method of producing ozone from interaction onan electromagnetic susceptor, comprises the steps of:

-   -   a. providing an electromagnetic susceptor having a matrix        material that is nonreflective of electromagnetic energy and        that surrounds a non-matrix material that is reflective of        electromagnetic energy and that is made from a material that is        different from the matrix material, wherein the non-matrix        material has exposed surfaces;    -   b. controlling the distance between the exposed surfaces of the        non-matrix material;    -   c. using a matrix material that has a low dielectric losses and        low dielectric constant; and    -   d. applying electromagnetic energy to the electromagnetic        susceptor to produce ozone.

1. A coated susceptor of electromagnetic energy for chemical processingcomprising: a matrix material that surrounds a non-matrix material thatis made from a material that is different from the matrix material,wherein the matrix material is constructed of material having lowerdielectric losses compared to the non-matrix material, wherein: a. thenon-matrix material initially absorbs electromagnetic energy applied tothe electromagnetic susceptor to a greater extent than the matrixmaterial; b. the non-matrix material produces subsequent heat in thematrix material; and c. the surface of the susceptor is coated with amaterial that interacts with applied electromagnetic energy of at leastone frequency and initially absorbs electromagnetic energy and producesheat.
 2. The coated susceptor of electromagnetic energy as claimed inclaim 1, wherein the form of said coating is selected from the groupconsisting of a full coating on all susceptor surfaces, a full coatingon a surface, a partial coating on a surface, a partial coating on allsusceptor surfaces, a coating with a specific pattern, a coatingcontaining a homogeneous material, a coating containing a compositematerial, a partial coating containing a more than one material, apatterned coating containing more than one material, a coatingcontaining multiple layers of different material, and combinationsthereof.
 3. The coated susceptor of electromagnetic energy as claimed inclaim 1, wherein the weight fraction of said non-matrix material isgreater than 0.00001 weight percent and less than 50 weight percent. 4.The coated susceptor of electromagnetic energy as claimed in claim 1,wherein the weight fraction of said non-matrix material is greater than50 weight percent and less 99.9 weight percent.
 5. The coated susceptorof electromagnetic energy as claimed in claim 1, wherein said coatinghas optical dielectric properties in relation to the appliedelectromagnetic energy selected from the group consisting oftransparent, reflective, scattering, absorptive, and combinationsthereof.
 6. The coated susceptor of electromagnetic energy as claimed inclaim 1, wherein said coating provides a utility to effect a physicalproperty of said susceptor selected from the group consisting ofmechanical properties, thermal properties, optical properties of thenon-matrix material, optical properties of the susceptor, absorption ofelectromagnetic energy, reflection of electromagnetic energy,transmission of electromagnetic energy, scattering of electromagneticenergy, electromagnetic properties, corrosive properties, wearproperties, piezoelectric properties, dielectric properties, magneticproperties, electric properties, susceptibility to the appliedelectromagnetic energy, susceptibility to the fluorescentelectromagnetic energy, conductivity, controlling the chemicalcompatibility between the non-matrix material and the matrix material,regulating the temperature of said susceptor, regulating the temperatureof a process, regulating the amount of electromagnetic energy availablefor chemical process, regulating the amount of electromagnetic energyavailable for a physical process, and combinations thereof.
 7. Thecoated susceptor of electromagnetic energy as claimed in claim 1,wherein said physical properties are controlled by the thickness of thecoating.
 8. The coated susceptor of electromagnetic energy as claimed inclaim 1, wherein said susceptor is used in an atmosphere selected fromthe group consisting of a reducing atmosphere, an oxidizing atmosphere,an atmosphere at one atmosphere of pressure, an atmosphere at less thanone atmosphere of pressure, an atmosphere at greater than one atmosphereof pressure, and combinations thereof.
 9. The coated susceptor ofelectromagnetic energy as claimed in claim 1, wherein said coating isconstructed of a material selected from the group consisting ofmetallic, amorphous, polycrystalline, antiferromagnetic,antiferroelectric, paramagnetic, a material with a Curie temperature,glassy, metallic, ferrimagnetic, ferroelectric, ferromagnetic,semiconducting, conducting, a solid-state ionic conductor, anon-stoichiometric carbide, a non-stoichiometric oxide, an oxycarbide, amaterial that produces thermionic emissions, a material that isthermoelectric, a cermet, a ceramic glaze with metal particles, anoxynitride, a carbonitride, an intermetallic, a hydroxide, anon-stoichiometric nitride, thermoluminescent, a composite material, anorganic polymeric matrix composite, a ceramic matrix composite, a metalmatrix composite, a crystalline form of silica, fused silica, quartz, aorganic copolymer, an amorphous organic polymer, a crystalline organicpolymer, polycarbonate, polypropylene, polystyrene, polyethylene,polyester, polytetrafluoroethylene, a non-stoichiometric llmeniticstructure, fluorescent, an artificial dielectric material, an artificialdielectric material where the volume fraction of the non-matrix speciesis less that 50 volume percent, an artificial dielectric material wherethe volume fraction of the non-matrix species is equal to or greaterthan 50 volume percent, a boride, a material with low dielectricconstant and low dielectric losses, a material with a high dielectricconstant and low dielectric losses, a silicide, a nitride, an aluminide,a material with a high dielectric constant and high dielectric losses, amaterial with a high dielectric constant and moderate dielectric losses,a carbide, an oxide, anatase, a sulfide, a sulfate, a crystalline formof silica, a carbonate, a glass ceramic, photochromatic,thermochromatic, a phase separated glass, an ionic conductor, a materialderived by processing a clay mineral with heat to a temperature and fortime period above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline and/or glass phases, a material derived by processing talcwith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the talcmaterial to non-reversible crystalline and/or glass, a material derivedby processing a zeolite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the zeolite material to non-reversible crystallineand/or glass phases, a material derived by processing Brucite with heatto a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the Brucite material tonon-reversible crystalline material, and a material derived byprocessing a Gibbsite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the clay material to non-reversible crystallinematerial or combination thereof.
 10. The coated susceptor ofelectromagnetic energy as claimed in claim 9, wherein said coating isconstructed of a clay mineral selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite and combinations thereof.
 11. The coated susceptorof electromagnetic energy as claimed in claim 1, wherein said coating isconstructed of a material selected from the group consisting of FeO, CuOCu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂, Cu₂O—MnO₂, Li₂O—Cu₂O,Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, Li₂O-NiO, TiO₂ doped with a divalentcation, TiO₂ doped with a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, TiO,Ti₂O₃, non-stoichiometric zirconia oxide, anatase, beta″-alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na,Li)-beta-alumina,carbon, graphite, ZnO, CuS, FeS, CoO, calcium aluminate, char, Ni, Co,Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), andcombinations thereof.
 12. The coated susceptor of electromagnetic energyas claimed in claim 1, wherein said coating is an amorphous materialthat is at a temperature below the material's glass transitiontemperature during the chemical processing.
 13. The coated susceptor ofelectromagnetic energy as claimed in claim 1, wherein the frequency ofsaid applied electromagnetic energy is selected from the groupconsisting of visible, ultraviolet, radio frequency, microwave,infrared, a variable frequency source, 915 MHz, 2.59 GHz, andcombinations thereof.
 14. The coated susceptor of electromagnetic energyas claimed in claim 1, wherein the structure of said susceptor isselected from the group consisting of chiral-shaped, spire-like shaped,helical shaped, rod-like shaped, plate-like shaped, acicular shaped,spherical shaped, ellipsoidal shaped, disc-shaped, irregular-shaped,plate-like shaped, a shape of a spiral antenna species for at least onewavelength of applied electromagnetic energy, a shape of an antennaspecified for at least on wavelength of applied electromagnetic energy,needle-like shaped, twist shaped, rotini shaped, a woven structure andhoneycomb-like structure, multi-cell structure, cylindrical shaped,tubular shaped, a reticulated structure, a foamed structure, a capillarystructure, and combinations thereof.
 15. The coated susceptor ofelectromagnetic energy as in claim 14, wherein the coated susceptor ispermeable to a chemical species flow.
 16. The coated susceptor ofelectromagnetic energy as claimed in claim 1, wherein the coatedsusceptor is used as a plurality of susceptors for chemical processingin the form of an operation selected from the group consisting offluidized bed, a slurry, a fluid mixture of susceptors and chemicalsspecies flow, a gaseous mixture of particulate susceptors and a chemicalspecies flow, a packed bed, a solid mixture of particulate susceptorsand a solid chemical species flow, and combination thereof.
 17. Thecoated susceptor of electromagnetic energy as claimed in claim 1,wherein said coating becomes reflective at the operating temperature ofthe chemical processing.
 18. The coated susceptor of electromagneticenergy as claimed in claim 1, further comprising a field concentratorwherein the location of the field concentrator is selected group fromthe group consisting of on the coating, embedded in the coating, in thecoating, and combinations thereof.
 19. The coated susceptor ofelectromagnetic energy as claimed in claim 1, wherein said coating isfunction is selected from the group consisting of driving chemicalreactions, assisting in chemical reactions, polymerization, producingbiodiesel through catalysis, synthesizing pharmaceuticals, reducingnitrogen oxides to nitrogen (N₂), reducing NO to nitrogen (N₂), reducingNO₂ to NO, reducing NO₂ to nitrogen (N₂), reducing SO_(x) to sulfur (S),reducing SO₃ to SO₂, reducing SO₄ to SO₂, reducing SO₃ to SO₂, chemicalsynthesis, sterilization, cracking hydrocarbons, decreasing theactivation energy of a chemical process, oxidizing volatile organiccompounds, oxidizing carbon monoxide to carbon dioxide, reducing NOx inthe presence of hydrocarbons, synthesizing biodiesel, reforming ahydrocarbon with a hydrogen donor species in the presence of H₂₃,reforming a hydrocarbon with methane in the presence of H₂₃, reforming ahydrocarbon in the presence of methane, water and carbon dioxide,reforming a hydrocarbon in the presence of methane, water, hydrogen andcarbon dioxide, reforming a hydrocarbon in the presence of hydrogen andmethane, polymerizing a hydrocarbon in the presence of metal halides,reducing nitrogen oxides in the presence of ammonia, reducing nitrogenoxides in the presence of ammonium-containing compounds, treatingpollutants to form clean air which can be discharged into theenvironment in accordance to the law of the land, oxidative bondcleavage of a hydrocarbon, non-oxidative bond cleavage of a hydrocarbon,catalysis, field concentration or combination thereof, wherein thereaction occurs in physical phases of matter from the group consistingof a plasma, gas, solid, liquid, a fluid containing particulates, andcombinations thereof.
 20. The coated susceptor of electromagnetic energyas claimed in claim 1, wherein the operating temperature of saidsusceptor is selected from the group of operating conditions consistingof a temperature which is above the Curie temperature of all thesusceptor's materials, a temperature which is below the Curietemperature of all the susceptor's materials, a temperature which isabove Curie temperature of the non-matrix material only, a temperaturewhich is above the Curie temperature of the matrix material only, atemperature which is above the Curie temperature of all the susceptor'smaterials causing increased absorption, a temperature which is above theCurie temperature of the non-matrix causing increased absorption, atemperature which is above the Curie temperature of the matrix causingincreased absorption, a temperature above the thermal runawaytemperature (critical temperature) of at least one of the constituentphases, a temperature which is below the thermal runaway temperature(critical temperature) of all the constituent phases, a temperaturewhich is below the activation temperature of the intrinsic dielectricconduction species of all the phases present, a temperature which isabove the activation temperature of at least one intrinsic dielectricconducting species of all constituent phases, a temperature above theCurie temperature of the coating's material, a temperature which isbelow the activation temperature of all extrinsic dielectric conductingspecies, a temperature which is above the activation temperature of atleast one extrinsic dielectric conducting species of all the constituentphases, and combinations thereof.
 21. The coated susceptor ofelectromagnetic energy as claimed in claim 1, wherein said coating isselected from the group consisting of controlling the amount ofabsorption of the applied electromagnetic energy by said susceptormaterial, regulating the temperature of the susceptor, controlling theamount of reflectivity of the applied electromagnetic energy by saidsusceptor, and combinations thereof.
 22. The coated susceptor ofelectromagnetic energy as claimed in claim 1 where the appliedelectromagnetic energy is applied in the form of continuous energy,pulsed energy or a combination thereof.
 23. The coated susceptor ofelectromagnetic energy as claimed in claim 1, wherein said coatingcontains a material with catalytic properties.
 24. The coated susceptorof electromagnetic energy as claimed in claim 23, wherein the materialwith catalytic properties has a molecular structure selected from thegroup consisting of amorphous, rock salt, zinc blend, antifluorite,rutile, perovskite, spinel, inverse spinel, nickel arsenide, corundum,ilimenite, olivine, cesium chloride, fluorite, silica types, wurtzite,derivative structure of a known crystalline structure, a superstructureof a known crystalline structure, orthosilicate, metasilicate, gibbsite,graphite, zeolite, carbide, nitride, montmorillonite, pyrophyllite,intermetallic semiconductor, metallic semiconductor, garnet,psuedoperovskite, orthoferrite, hexagonal ferrite, rare earth garnet,and a ferrite.
 25. The coated susceptor of electromagnetic energy asclaimed in claim 23, wherein the material with catalytic properties haselectronic properties selected from the group consisting of a p-typematerial, an n-type material, a cation-doped p-type dominate material,an anion-doped p-type dominate materials, a cation-doped n-type dominatematerial, an anion-doped n-type material, and combinations thereof. 26.The coated susceptor of electromagnetic energy as claimed in claim 23,wherein a barrier coating is place between said coating material withcatalytic properties and said susceptor to prevent deleterious chemicalreaction between said coating material with catalytic properties and thesusceptor, to help prevent the poisoning of the catalyst, or to helpprevent a combination thereof.
 27. The coated susceptor ofelectromagnetic energy as claimed in claim 23, wherein the form of thecatalytic material is selected from the group consisting of a catalystthat is a full coating on all susceptor surfaces, a catalyst that ispartial coating on all susceptor surfaces, a catalyst that isparticulate catalyst on the susceptor's surface, a catalyst that isparticulate catalyst contained in a coating that is on the susceptor, acatalyst that is particulate catalyst on a coating that is on thesusceptor, a catalyst that is full coating of all susceptor surfacesthat has an additional coating between the catalyst and the susceptor, acatalyst that is a partial coating of all susceptor surfaces that has anadditional coating between the catalyst and the susceptor, andcombinations thereof.
 28. The coated susceptor of electromagnetic energyas claimed in claim 23, wherein the material with catalytic propertiesis a composite selected from the group of catalytic compositesconsisting of two or more catalysts that perform the same function, twoor more catalysts where at least one catalyst performs a differentfunction than the other catalyst, two or more catalysts where at leastone catalyst is a metallic species, two or more catalyst where at leastone catalyst has a Curie temperature, and combinations thereof.
 29. Thecoated susceptor of electromagnetic energy as claimed in claim 23,wherein the material with catalytic properties has a function isselected from the group consisting of driving chemical reactions,assisting in chemical reactions, polymerization, producing biodieselthrough catalysis, synthesizing pharmaceuticals, reducing nitrogenoxides to nitrogen (N₂), reducing NO to nitrogen (N₂), reducing NO₂ toNO, reducing NO₂ to nitrogen (N₂), reducing SO_(x) to sulfur (S),reducing SO₃ to SO₂, reducing SO₄ to SO₂, reducing SO₃ to SO₂, chemicalsynthesis, sterilization, cracking hydrocarbons, decreasing theactivation energy of a chemical process, oxidizing volatile organiccompounds, oxidizing carbon monoxide to carbon dioxide, reducing NOx inthe presence of hydrocarbons, synthesizing biodiesel, reforming ahydrocarbon with a hydrogen donor species in the presence of H₂₃,reforming a hydrocarbon with methane in the presence of H₂₃, reforming ahydrocarbon in the presence of methane, water and carbon dioxide,reforming a hydrocarbon in the presence of methane, water, hydrogen andcarbon dioxide, reforming a hydrocarbon in the presence of hydrogen andmethane, polymerizing a hydrocarbon in the presence of metal halides,reducing nitrogen oxides in the presence of ammonia, reducing nitrogenoxides in the presence of ammonium-containing compounds, treatingpollutants to form clean air which can be discharged into theenvironment in accordance to the law of the land, oxidative bondcleavage of a hydrocarbon, non-oxidative bond cleavage of a hydrocarbon,catalysis, field concentration or combination thereof, wherein thereaction occurs in physical phases of matter from the group consistingof a plasma, gas, solid, liquid, a fluid containing particulates, andcombinations thereof.
 30. The coated susceptor of electromagnetic energyas claimed in claim 23, wherein the material with catalytic propertiesis selected from the group of materials consisting of a photocatalyticmaterial activated by electromagnetic energy in the ultraviolet region,a photo catalytic material activated by electromagnetic energy in thevisible region, a infrared catalytic materials activated byelectromagnetic energy in the infrared region, a catalytic materialsactivated by electromagnetic energy in the microwave region, a catalyticmaterial activated by electromagnetic energy in the radio frequencyregion, and combinations thereof.
 31. The coated susceptor ofelectromagnetic energy as claimed in claim 23, where the material withcatalytic properties is selected from the group of consisting ofmaterials that are a precious metal, Fe, Co, Ni, Pt, Pd, Au, Ag,chalcogenide, metal alloy, boride, Fe-based alloy, a precious metalalloy, an artificial dielectric, an artificial dielectric material wherethe volume fraction of the non-matrix species is less that 50 volumepercent, an artificial dielectric material where the volume fraction ofthe non-matrix species is equal to or greater than 50 volume percent,Co-alloy, Ni-alloy, antiferromagnetic, antiferroelectric, paramagnetic,a material with a Curie temperature, glassy, metallic, a material thatproduces thermionic emissions, a material that is thermoelectric, acermet, a ceramic glaze with metal particles, ferrimagnetic,ferroelectric, ferromagnetic, semiconducting, conducting, solid-stateionic conductor, non-stoichiometric carbide, non-stoichiometric oxide,oxycarbide, oxynitride, carbonitride, oxide, nitride, intermetallic,hydroxide, thermoluminescent, fluorescent, boride, a material with lowdielectric constant and low dielectric losses, a material with a highdielectric constant and low dielectric losses, silicide, nitride,aluminide, a material with a high dielectric constant and highdielectric losses, a material with a high dielectric constant andmoderate dielectric losses, carbide, oxide, anatase, sulfide, sulfate,carbonate, FeO, CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂,Li2O—NiO, TiO₂ doped with a divalent cation, TiO₂ doped with a trivalentcation, Fe₂O₃ doped with Ti⁺⁴, Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO,Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, TiO, Ti₂O₃, non-stoichiometriczirconia oxide, anatase, beta″-alumina, alpha-alumina, Na-beta-alumina,Li-beta-alumina, (Na,Li)-beta-alumina, carbon, graphite, ZnO, CuS, FeS,CoO, calcium aluminate, char, Ni, Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃,NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃, MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x),CoTiO_(3-x), FeTiO_(3-x), ZnO_(1-x), SmLiO₂, LaLiO₂, LaNaO₂, SmNaO₂,(SmLiO₂)_(0.8)(CaOMgO)_(0.2), (LaLi₂)_(0.7)(SrOMgO)_(0.3),(NdLiO₂)_(0.8)(CaMgO)_(0.2), strontium-doped lanthium oxide supported onmagnesium oxide, a material derived by processing a clay mineral withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline and/or glass phases, a material derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to non-reversible crystalline and/or glass, a materialderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, a material derived by processingBrucite with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe Brucite material to non-reversible crystalline material, a materialderived by processing a Gibbsite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline material, and combinations thereof.
 32. The coated susceptorof electromagnetic energy as claimed in claim 31, wherein the claymineral is selected from the group consisting of a montmorillonite, aball clay, illite, dickite, halloysite, a mica, a zeolite, a koalinite,an illitic clay, pyropholite, Endellite, bentonite, chlorite, andcombinations thereof.
 33. The coated susceptor of electromagnetic energyas claimed in claim 1, wherein the coating on the susceptor is used as areactant with a chemical species flow for desired products or with apollutant species to treat pollutants for producing clean air which canbe discharge into the environment in accordance with the law of theland.
 34. The coated susceptor of electromagnetic energy as claimed inclaim 33, wherein the coating is a carbon-containing species that reactswith a chemical species flow to produce hydrogen, higher order chemicalspecies, lower order chemical species, carbon monoxide, carbon dioxideor combinations thereof.
 35. The coated susceptor of electromagneticenergy as claimed in claim 33, wherein where the coating contains areactant selected from the group consisting of Na-beta alumina, Li-betaalumina, NaOH, LiOH, CaCO₃, Ca(OH)₂, gamma-alumina, alpha-alumina,lithium complexes, a lithium complex partially adsorbed on partiallycalcine bauxite, a sodium complex partially adsorbed on partiallycalcine bauxite, silica, a cation-doped silica or combination thereof,to chemically react with a chemical species flow containing a fluorinespecies, a chlorine species, a sulfur species, and combinations thereof.36. The coated susceptor of electromagnetic energy as claimed in claim33, wherein the coating contains a reactant selected from the groupconsisting of urea, ammonia, cyanuric acid, ammonium carbamate, ammoniumbicarbonate, mixtures of ammonia and ammonium bicarbonate, ammoniumformate, ammoniumoxialate, sources of a nydroxyl radicals, sources ofhydrogen radicals, milk, sugar, molasses, polysaccharides, a reducingagent, and combinations thereof, to chemically react with a chemicalspecies flow containing a nitrogen oxide or nitrogen oxides to produceNitrogen (N₂).
 37. A coated susceptor of electromagnetic energy forchemical processing comprising: a matrix material that surroundsnon-matrix material that is made from a material that is different fromthe matrix material, wherein the matrix material is constructed ofmaterial having lower dielectric losses compared to the non-matrixmaterial, wherein: a. the non-matrix material initially absorbselectromagnetic energy applied to the electromagnetic susceptor to agreater extent than the matrix material; b. the non-matrix materialproduces subsequent heat in the matrix material and produces reflection;and c. the surface of the susceptor is a coated with a material thatinteracts with applied electromagnetic energy of at least one frequencyand initially absorbs electromagnetic energy and produces heat.
 38. Thecoated susceptor of electromagnetic energy as claimed in claim 37,wherein the form of said coating is selected from the group consistingof a full coating on all susceptor surfaces, a full coating on asurface, a partial coating on a surface, a partial coating on allsusceptor surfaces, a coating with a specific pattern, a coatingcontaining a homogeneous material, a coating containing a compositematerial, a partial coating containing a more than one material, apatterned coating containing more than one material, a coatingcontaining multiple layers of different material, and combinationsthereof.
 39. The coated susceptor of electromagnetic energy as claimedin claim 37, wherein the weight fraction of said non-matrix material isgreater than 0.00001 weight percent and less than 50 weight percent. 40.The coated susceptor of electromagnetic energy as claimed in claim 37,wherein the weight fraction of said non-matrix material is greater than50 weight percent and less 99 weight percent.
 41. The coated susceptorof electromagnetic energy as claimed in claim 37, wherein said coatinghas optical dielectric properties in relation to the appliedelectromagnetic energy selected from the group consisting oftransparent, reflective, scattering, absorptive, and combinationsthereof.
 42. The coated susceptor of electromagnetic energy as claimedin claim 37, wherein said coating provides a utility to effect aphysical property of said susceptor selected from the group consistingof mechanical properties, thermal properties, optical properties of thenon-matrix material, optical properties of the susceptor, absorption ofelectromagnetic energy, reflection of electromagnetic energy,transmission of electromagnetic energy, scattering of electromagneticenergy, electromagnetic properties, corrosive properties, wearproperties, piezoelectric properties, dielectric properties, magneticproperties, electric properties, susceptibility to the appliedelectromagnetic energy, susceptibility to the fluorescentelectromagnetic energy, conductivity, controlling the chemicalcompatibility between the non-matrix material and the matrix material,regulating the temperature of said susceptor, regulating the temperatureof a process, regulating the amount of electromagnetic energy availablefor chemical process, regulating the amount of electromagnetic energyavailable for a physical process, and combinations thereof.
 43. Thecoated susceptor of electromagnetic energy as in claim 37, wherein saidphysical properties are controlled by the thickness of the coating. 44.The coated susceptor of electromagnetic energy as claimed in claim 37,wherein said susceptor is used in an atmosphere selected from the groupconsisting of a reducing atmosphere, an oxidizing atmosphere, anatmosphere at one atmosphere of pressure, an atmosphere at less than oneatmosphere of pressure, an atmosphere at greater than one atmosphere ofpressure, and combinations thereof.
 45. The coated susceptor ofelectromagnetic energy as claimed in claim 37, wherein said coating isconstructed of a material selected from the group consisting ofmetallic, amorphous, polycrystalline, antiferromagnetic,antiferroelectric, paramagnetic, a material with a Curie temperature,glassy, metallic, ferrimagnetic, ferroelectric, ferromagnetic,semiconducting, conducting, a solid-state ionic conductor, a materialthat produces thermionic emissions, a material that is thermoelectric, acermet, a ceramic glaze with metal particles, a non-stoichiometriccarbide, a non-stoichiometric oxide, an oxycarbide, an oxynitride, acarbonitride, an intermetallic, a hydroxide, a non-stoichiometricnitride, thermoluminescent, a non-stoichiometric Ilmenitic structure,fluorescent, an artificial dielectric material, an artificial dielectricmaterial where the volume fraction of the non-matrix species is lessthat 50 volume percent, an artificial dielectric material where thevolume fraction of the non-matrix species is equal to or greater than 50volume percent, a boride, a material with low dielectric constant andlow dielectric losses, a material with a high dielectric constant andlow dielectric losses, a silicide, a nitride, an aluminide, a materialwith a high dielectric constant and high dielectric losses, a materialwith a high dielectric constant and moderate dielectric losses, acarbide, an oxide, anatase, a sulfide, a sulfate, a crystalline form ofsilica, a carbonate, a glass ceramic, photochromatic, thermochromatic, acomposite material, an organic polymeric matrix composite, a ceramicmatrix composite, a metal matrix composite, a crystalline form ofsilica, fused silica, quartz, a organic copolymer, an amorphous organicpolymer, a crystalline organic polymer, polycarbonate, polypropylene,polystyrene, polyethylene, polyester, polytetrafluoroethylene, a phaseseparated glass, an ionic conductor, a material derived by processing aclay mineral with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe clay material to non-reversible crystalline and/or glass phases, amaterial derived by processing talc with heat to a temperature and fortime period above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the talc material to non-reversiblecrystalline and/or glass, a material derived by processing a zeolitewith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the zeolitematerial to non-reversible crystalline and/or glass phases, a materialderived by processing Brucite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the Brucite material to non-reversiblecrystalline material, a material derived by processing a Gibbsite withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline material, and combinations thereof.
 46. Thecoated susceptor of electromagnetic energy as claimed in claim 45,wherein the clay mineral is selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite, and combinations thereof.
 47. The coated susceptorof electromagnetic energy as claimed in claim 37, wherein said coatingis constructed of a material selected from the group consisting of FeO,CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂, Cu₂O—MnO₂, Li₂O—Cu₂O,Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, Li₂O—NiO, TiO₂ doped with a divalentcation, TiO₂ doped with a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, TiO,Ti₂O₃, non-stoichiometric zirconia oxide, anatase, beta″-alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na,Li)-beta-alumina,carbon, graphite, ZnO, CuS, FeS, CoO, calcium aluminate, char, Ni, Co,Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), andcombinations thereof.
 48. The coated susceptor of electromagnetic energyas claimed in claim 37, wherein said coating is an amorphous materialthat is at a temperature below the material's glass transitiontemperature during the chemical processing.
 49. The coated susceptor ofelectromagnetic energy as claimed in claim 37, wherein the frequency ofsaid applied electromagnetic energy is selected from the groupconsisting of visible, ultraviolet, radio frequency, microwave,infrared, a variable frequency source, 915 MHz, 2.59 GHz, andcombinations thereof.
 50. The coated susceptor of electromagnetic energyas claimed in claim 37, wherein the structure of said susceptor isselected from the group consisting of chiral-shaped, spire-like shaped,helical shaped, rod-like shaped, plate-like shaped, acicular shaped,spherical shaped, ellipsoidal shaped, disc-shaped, irregular-shaped,plate-like shaped, a shape of a spiral antenna species for at least onewavelength of applied electromagnetic energy, shape of an antennaspecified for at least on wavelength of applied electromagnetic energy,needle-like shaped, twist shaped, rotini shaped, a woven structure andhoneycomb-like structure, multi-cell structure, cylindrical shaped,tubular shaped, a reticulated structure, a foamed structure, a capillarystructure, and combinations thereof.
 51. The coated susceptor ofelectromagnetic energy as claimed in claim 50, wherein the coatedsusceptor is permeable to a chemical species flow.
 52. The coatedsusceptor of electromagnetic energy as claimed in claim 37, wherein thecoated susceptor is used as a plurality of susceptors for chemicalprocessing in the form of an operation selected from the groupconsisting of a fluidized bed, a slurry, a fluid mixture of susceptorsand chemicals species flow, a gaseous mixture of particulate susceptorsand a chemical species flow, a packed bed, a solid mixture ofparticulate susceptors and a solid chemical species flow, andcombinations thereof.
 53. The coated susceptor of electromagnetic energyas claimed in claim 37, wherein said coating becomes reflective at theoperating temperature of the chemical processing.
 54. The coatedsusceptor of electromagnetic energy as claimed in claim 37, furthercomprising a field concentrator wherein the location of the fieldconcentrator is selected from the group consisting of on the coating,embedded in the coating, in the coating, and combinations thereof. 55.The coated susceptor of electromagnetic energy as claimed in claim 37,wherein said coating has a function selected from the group consistingof driving chemical reactions, assisting in chemical reactions,polymerization, producing biodiesel through catalysis, synthesizingpharmaceuticals, reducing nitrogen oxides to nitrogen (N₂), reducing NOto nitrogen (N₂), reducing NO₂ to NO, reducing NO₂ to nitrogen (N₂),reducing SO_(x) to sulfur (S), reducing SO₃ to SO₂, reducing SO₄ to SO₂,reducing SO₃ to SO₂, chemical synthesis, sterilization, crackinghydrocarbons, decreasing the activation energy of a chemical process,oxidizing volatile organic compounds, oxidizing carbon monoxide tocarbon dioxide, reducing NOx in the presence of hydrocarbons,synthesizing biodiesel, reforming a hydrocarbon with a hydrogen donorspecies in the presence of H₂₃, reforming a hydrocarbon with methane inthe presence of H₂₃, reforming a hydrocarbon in the presence of methane,water and carbon dioxide, reforming a hydrocarbon in the presence ofmethane, water, hydrogen and carbon dioxide, reforming a hydrocarbon inthe presence of hydrogen and methane, polymerizing a hydrocarbon in thepresence of metal halides, reducing nitrogen oxides in the presence ofammonia, reducing nitrogen oxides in the presence of ammonium-containingcompounds, treating pollutants to form clean air which can be dischargedinto the environment in accordance to the law of the land, oxidativebond cleavage of a hydrocarbon, non-oxidative bond cleavage of ahydrocarbon, catalysis, field concentration or combination thereof,wherein the reaction occurs in physical phases of matter from the groupconsisting of a plasma, gas, solid, liquid, a fluid containingparticulates, and combinations thereof.
 56. The coated susceptor ofelectromagnetic energy as claimed in claim 37, wherein the operatingtemperature of said susceptor is selected from the group of operatingconditions consisting of a temperature which is above the Curietemperature of all the susceptor's materials, a temperature which isbelow the Curie temperature of all the susceptor's materials, atemperature which is above Curie temperature of the non-matrix materialonly, a temperature which is above the Curie temperature of the matrixmaterial only, a temperature which is above the Curie temperature of allthe susceptor's materials causing increased absorption, a temperaturewhich is above the Curie temperature of the non-matrix causing increasedabsorption, a temperature which is above the Curie temperature of thematrix causing increased absorption, a temperature above the thermalrunaway temperature (critical temperature) of at least one of theconstituent phases, a temperature which is below the thermal runawaytemperature (critical temperature) of all the constituent phases, atemperature which is below the activation temperature of the intrinsicdielectric conduction species of all the phases present, a temperaturewhich is above the activation temperature of at least one intrinsicdielectric conducting species of all constituent phases, a temperatureabove the Curie temperature of the coating's material, a temperaturewhich is below the activation temperature of all extrinsic dielectricconducting species, a temperature which is above the activationtemperature of at least one extrinsic dielectric conducting species ofall the constituent phases, and combinations thereof.
 57. The coatedsusceptor of electromagnetic energy as claimed in claim 37, wherein saidcoating is selected from the group consisting of controlling the amountof absorption of the applied electromagnetic energy by said susceptormaterial, regulating the temperature of the susceptor, controlling theamount of reflectivity of the applied electromagnetic energy by saidsusceptor, or a combination thereof.
 58. The coated susceptor ofelectromagnetic energy as claimed in claim 37, wherein the appliedelectromagnetic energy is applied in the form of continuous energy,pulsed energy or a combination thereof.
 59. The coated susceptor ofelectromagnetic energy as claimed in claim 37, wherein said coatingcontains a material with catalytic properties.
 60. The coated susceptorof electromagnetic energy as claimed in claim 59, wherein the materialwith catalytic properties has a molecular structure selected from thegroup consisting of amorphous, rock salt, zinc blend, antifluorite,rutile, perovskite, spinel, inverse spinel, nickel arsenide, corundum,ilimenite, olivine, cesium chloride, fluorite, silica types, wurtzite,derivative structure of a known crystalline structure, a superstructureof a known crystalline structure, orthosilicate, metasilicate, gibbsite,graphite, zeolite, carbide, nitride, montmorillonite, pyrophyllite,intermetallic semiconductor, metallic semiconductor, garnet,psuedoperovskite, orthoferrite, hexagonal ferrite, rare earth garnet,and ferrite.
 61. The coated susceptor of electromagnetic energy asclaimed in claim 59, wherein the material with catalytic properties haselectronic properties selected from the group consisting of a p-typematerial, an n-type material, a cation-doped p-type dominate material,an anion-doped p-type dominate materials, a cation-doped n-type dominatematerial, an anion-doped n-type material, and combinations thereof. 62.The coated susceptor of electromagnetic energy as claimed in claim 59,wherein a barrier coating is place between said coating material withcatalytic properties and said susceptor to prevent deleterious chemicalreaction between said coating material with catalytic properties and thesusceptor, to help prevent the poisoning of the catalyst, and to preventcombination thereof.
 63. The coated susceptor of electromagnetic energyas claimed in claim 59, wherein the material with catalytic propertieshas a form selected from the group consisting of a catalyst that is afull coating on all susceptor surfaces, a catalyst that is partialcoating on all susceptor surfaces, a catalyst that is particulatecatalyst on the susceptor's surface, a catalyst that is particulatecatalyst contained in a coating that is on the susceptor, a catalystthat is particulate catalyst on a coating that is on the susceptor, acatalyst that is full coating of all susceptor surfaces that has anadditional coating between the catalyst and the susceptor, a catalystthat is a partial coating of all susceptor surfaces that has anadditional coating between the catalyst and the susceptor, andcombinations thereof.
 64. The coated susceptor of electromagnetic energyas claimed in claim 59, wherein the material is a composite selectedfrom the group consisting of catalytic composites consisting of two ormore catalysts that perform the same function, two or more catalystswhere at least one catalyst performs a different function than the othercatalyst, two or more catalysts where at least one catalyst is ametallic species, two or more catalyst where at least one catalyst has aCurie temperature, and combinations thereof.
 65. The coated susceptor ofelectromagnetic energy as claimed in claim 59, wherein the material withcatalytic properties has a function selected from the group consistingof driving chemical reactions, assisting in chemical reactions,polymerization, producing biodiesel through catalysis, synthesizingpharmaceuticals, reducing nitrogen oxides to nitrogen (N₂), reducing NOto nitrogen (N₂), reducing NO₂ to NO, reducing NO₂ to nitrogen (N₂),reducing SO_(x) to sulfur (S), reducing SO₃ to SO₂, reducing SO₄ to SO₂,reducing SO₃ to SO₂, chemical synthesis, sterilization, crackinghydrocarbons, decreasing the activation energy of a chemical process,oxidizing volatile organic compounds, oxidizing carbon monoxide tocarbon dioxide, reducing NOx in the presence of hydrocarbons,synthesizing biodiesel, reforming a hydrocarbon with a hydrogen donorspecies in the presence of H₂₃, reforming a hydrocarbon with methane inthe presence of H₂₃, reforming a hydrocarbon in the presence of methane,water and carbon dioxide, reforming a hydrocarbon in the presence ofmethane, water, hydrogen and carbon dioxide, reforming a hydrocarbon inthe presence of hydrogen and methane, polymerizing a hydrocarbon in thepresence of metal halides, reducing nitrogen oxides in the presence ofammonia, reducing nitrogen oxides in the presence of ammonium-containingcompounds, treating pollutants to form clean air which can be dischargedinto the environment in accordance to the law of the land, oxidativebond cleavage of a hydrocarbon, non-oxidative bond cleavage of ahydrocarbon, catalysis, field concentration or combination thereof,wherein the reaction occurs in physical phases of matter from the groupconsisting of a plasma, gas, solid, liquid, a fluid containingparticulates, and combinations thereof.
 66. The coated susceptor ofelectromagnetic energy as claimed in claim 59, wherein the material withcatalytic properties is selected from the group of materials consistingof a photocatalytic material activated by electromagnetic energy in theultraviolet region, a photo catalytic material activated byelectromagnetic energy in the visible region, a infrared catalyticmaterials activated by electromagnetic energy in the infrared region, acatalytic materials activated by electromagnetic energy in the microwaveregion, a catalytic material activated by electromagnetic energy in theradio frequency region, and combinations thereof.
 67. The coatedsusceptor of electromagnetic energy as claimed in claim 59, wherein thematerial with catalytic properties is selected from the group ofconsisting of materials that are a precious metal, Fe, Co, Ni, Pt, Pd,Au, Ag, chalcogenide, metal alloy, boride, Fe-based alloy, a preciousmetal alloy, an artificial dielectric, an artificial dielectric materialwhere the volume fraction of the non-matrix species is less that 50volume percent, an artificial dielectric material where the volumefraction of the non-matrix species is equal to or greater than 50 volumepercent, Co-alloy, Ni-alloy, antiferromagnetic, antiferroelectric,paramagnetic, a material with a Curie temperature, glassy, metallic,ferrimagnetic, ferroelectric, ferromagnetic, semiconducting, conducting,solid-state ionic conductor, non-stoichiometric carbide,non-stoichiometric oxide, oxycarbide, oxynitride, carbonitride, oxide,nitride, intermetallic, a material that produces thermionic emissions, amaterial that is thermoelectric, a cermet, a ceramic glaze with metalparticles, hydroxide, thermoluminescent, fluorescent, boride, a materialwith low dielectric constant and low dielectric losses, a material witha high dielectric constant and low dielectric losses, silicide, nitride,aluminide, a material with a high dielectric constant and highdielectric losses, a material with a high dielectric constant andmoderate dielectric losses, carbide, oxide, anatase, sulfide, sulfate,carbonate, FeO, CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂,Li2O—NiO, TiO₂ doped with a divalent cation, TiO₂ doped with a trivalentcation, Fe₂O₃ doped with Ti⁺⁴, Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO,Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, TiO, Ti₂O₃, non-stoichiometriczirconia oxide, anatase, beta″-alumina, alpha-alumina, Na-beta-alumina,Li-beta-alumina, (Na,Li)-beta-alumina, carbon, graphite, ZnO, CuS, FeS,CoO, calcium aluminate, char, Ni, Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃,NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃, MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x),CoTiO_(3-x), FeTiO_(3-x), ZnO_(1-x), SmLiO₂, LaLiO₂, LaNaO₂, SmNaO₂,(SmLiO₂)_(0.8)(CaOMgO)_(0.2), (LaLi₂)_(0.7)(SrOMgO)_(0.3),(NdLiO₂)_(0.8)(CaMgO)_(0.2), strontium-doped lanthium oxide supported onmagnesium oxide, a material derived by processing a clay mineral withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline and/or glass phases, a material derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to non-reversible crystalline and/or glass, a materialderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, a material derived by processingBrucite with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe Brucite material to non-reversible crystalline material, a materialderived by processing a Gibbsite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline material, and combinations thereof.
 68. The coated susceptorof electromagnetic energy as claimed in claim 67, wherein the claymineral is selected from the group consisting of a montmorillonite, aball clay, illite, dickite, halloysite, a mica, a zeolite, a koalinite,an illitic clay, pyropholite, Endellite, bentonite, chlorite, andcombinations thereof.
 69. The coated susceptor of electromagnetic energyas claimed in claim 37, wherein the coating on the susceptor is used asreactants with a chemical species flow for desired products or with apollutant species to treat pollutants for producing clean air which canbe discharge into the environment in accordance with the law of theland.
 70. The coated susceptor of electromagnetic energy as claimed inclaim 69, wherein the coating is a carbon-containing species that reactswith a chemical species flow to produce hydrogen, higher order chemicalspecies, lower order chemical species, carbon monoxide, carbon dioxideor combinations thereof.
 71. The coated susceptor of electromagneticenergy as claimed in claim 69, wherein where the coating contains areactant selected from the group consisting of Na-beta alumina, Li-betaalumina, NaOH, LiOH, CaCO₃, Ca(OH)₂, gamma-alumina, alpha-alumina,lithium complexes, a lithium complex partially adsorbed on partiallycalcine bauxite, a sodium complex partially adsorbed on partiallycalcine bauxite, silica, a cation-doped silica or combination thereof,to chemically react with a chemical species flow containing a fluorinespecies, a chlorine species, a sulfur species, and combinations thereof.72. The coated susceptor of electromagnetic energy as claimed in claim69, wherein the coating contains a reactant selected from the groupconsisting of urea, ammonia, cyanuric acid, ammonium carbamate, ammoniumbicarbonate, mixtures of ammonia and ammonium bicarbonate, ammoniumformate, ammoniumoxialate, sources of a nydroxyl radicals, sources ofhydrogen radicals, milk, sugar, molasses, polysaccharides, a reducingagent or combination thereof, to chemically react with a chemicalspecies flow containing a nitrogen oxide, and nitrogen oxides to produceNitrogen (N₂).